New in the forum and from Finland so there might be some spelling errors etc. but try to withstand, because I really need some advice.

Bought a K100RT last autumn. Drove something like 750km with it before winter and discovered that it leaks oil. Both transmission and engine. Well those leaks are being repaired (main crankseal fitted wrong and that clutch cup at the end of trasmission). The bike is torn to pieces and I replaced also some seals to the nose of the transmission.

And now. The problem. The screw thread (picked that from a dictionary) of the hole which contains the neutral detent ball and spring is bad. Bolt wont dock just spins. Well my bike was "a bit" customized by previous owner (and some more by me) and it does not have even neutral light nor gear indicator. So does that spring and ball do anything else but make those work?

Because if not, I can leave them completely out of transmission. Screw thread is fine deeper and longer bolt would seal the hole fine. Otherwise I think I have to find shorter spring to it.

Here is a pic or two of my K100 just in case someone wonders what it looks like.

http://kotisivu.dnainternet.net/ajk73/AF2.jpg
http://kotisivu.dnainternet.net/ajk73/AF4.jpg

Stil to do: (+ put it back together obviusly) sidepanels. They will be made from grey leather.

Welcome Tenox.

I have no idea about anything you just said, but that bike needs some serious looking.
More photos please.
Whoever had that before you has done a lot of work.
Chrome, red, Matt, black.
Wow.

Tenox wrote:New in the forum and from Finland so there might be some spelling errors Well my bike was "a bit" customized by previous owner (and some more by me) .

Yep Tenix I have never seen a K100 like yours...and I like what you have done with the metallic parts....I suggest you helicoil the hole so the thread is as new.......sometimes you can leave things out and sometimes not at all.

My learned collegues will no doubt say more...welcome friend.

All I've done so far are front light and licence plate holder and that airflow thingy near air intake + some electrical stuff (brakelights didnt work etc.) But about the pics:

http://kotisivu.dnainternet.net/ajk73/download.html (sorry that it is in finnish)

First 6 pics are from when I bought that, pics 7-10 temporary fixes done and final photoshopped pic is what the bike will look like summer 2013 (+ those leather panels)

Other project pics:
http://kotisivu.dnainternet.net/ajk73/AF1.jpg
http://kotisivu.dnainternet.net/ajk73/AF3.jpg
http://kotisivu.dnainternet.net/ajk73/AF5.jpg

http://kotisivu.dnainternet.net/ajk73/OF1.jpg
http://kotisivu.dnainternet.net/ajk73/O1.jpg
http://kotisivu.dnainternet.net/ajk73/OF3.jpg

http://kotisivu.dnainternet.net/ajk73/P1.jpg (just in case I have to do longer trip..)
http://kotisivu.dnainternet.net/ajk73/EV2.jpg

Edit: Frame, fueltank etc. are coated with teflon.

You need the detent ball and spring as they position the gears in neutral and prevent it from slipping back into 1st or 2nd easily so helicoil it and repair the thread correctly it is needed as it is.

Thanks for the info. I think I will repair it with some unorthodox metod, because if I have to open it again for some reason I think I should buy compeletely new cover. I dont want to open it again, and if I do new thread it would possibly send some metal scrap inside gearbox?

Remains to be seen. Shorter spring would be nice.

Edit: I think I'll put 7/16 thread and bolt in there. It's ~11mm, so it should do fine. Plan to prevent any metal scrap getting into transmission by manufacturing a 10mm (x10mm) headless bolt with screwdriver notch and screw it in to the hole first. I should be able to get it out afterwards because its smaller than new thread. How does this sound?

Tenox wrote: Plan to prevent any metal scrap getting into transmission

Whenever I have replaced a damaged thread I have always put a rag in the hole ( a short grub screw is clever) until the drilling is complete and then when cutting a new thread for the helicoil I use trefolex or a heavy grease which catches all swarf which is a nice soft alloy anyway...have done many spark plug holes and sump plugs this way.

Came in to my mind, that can you do a helicoil repair to a hole which cannot be drilled all the way open? The place where the ball and spring goes is lot thinner than thread section.

New 7/16 thread and bolt installed succesfully. Gearbox is now ready for assembly, clutch plate and main seal still missing. Got installed new Michelin Pilot Active tyres today.

Edit: Seal and clutch plate came! At Wednesday i will start putting this thing back together.