Pulled Cylinder Stud

[MCboston]

Unfortunately I have to repair a pulled cylinder stud on my 1992 R100GS. It is the right side, top exhaust which also holds the rocker assembly. The helicoil installed by a previous owner has sheared the threads off inside the case hole which measures +-11mm inside diameter. I am trying to refrain from drilling as there is not a lot of metal between stud hole and piston opening and just tapping new threads.
Please help me out with info, specifically which insert to use etc., thanks.

[Garnet]

There is a pretty good thread here: http://boxerworks.com/forum2/viewtopic.php?f=1&t=466
and a good pictoral by Frog here: http://picasaweb.google.com/blaisedesco ... 7sKaptKfQA#

[Deleted User 62]

http://www.cycleworks.net/ sells a tool for fixing pulled studs ($$$$$) and the correct inserts.

[MCboston]

One of the local airhead gurus told me that since the helicoil stripped the case nothing else will fix it and I have to replace the case?

[Garnet]

The case saver inserts and the other brand used by Frog are a lot bigger than Heli-coils, so I believe they can reapair the stripped Heli-coil. I think that is covered in part of that long thread.

[MCboston]

There is a pretty good thread here: http://boxerworks.com/forum2/viewtopic.php?f=1&t=466
and a good pictoral by Frog here: http://picasaweb.google.com/blaisedesco ... 7sKaptKfQA#

Thanks, but that does not address my issue of the previously installed helicoil striping the case

[MCboston]

Ok thanks, I will investigate these case savers

[esman100]

The Timeserts are much larger as mentioned above and I'm certain that they will work. If it doesn't then you can have an oversize insert machined at a machine shop or look at many other standard oversize insert sources. I would not replace the case.

[MCboston]

The Timeserts are much larger as mentioned above and I'm certain that they will work. If it doesn't then you can have an oversize insert machined at a machine shop or look at many other standard oversize insert sources. I would not replace the case.

With very little aluminum left between stud hole and cylinder opening I am trying to keep the insert size minimal, but appreciate any input and will have a look at the timeserts you mentioned. Any idea why Snowbum is against them?
And yes, I will try anything short of replacing the case as the engine as a whole is in great shape.

[Ross]

Same thing happened to me. Read and weep.... http://rossmz.blogspot.com/search/label ... der%20stud