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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.

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#

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

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?

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.

Garnet wrote: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

Ok thanks, I will investigate these case savers

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.

esman100 wrote: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.

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