GSX-R1100K Deco-mainte: Fuel petcock broken bolt removal

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We’ve strayed quite a bit from the original request. If we did everything properly, there’d be no end to it and the budget would really add up, so we’re proceeding carefully to get the bike discharged in good shape.

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Quite troublesome powder rust. Whether it’s large or fine, it causes problems.

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It’s built up nicely inside the float valve too.

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Fine powder rust causes a nasty slow overflow. The powder rust catches on the float valve and doesn’t seal quite right, so fuel drips and trickles out.

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At this level, replacement isn’t necessary, so we’ll reuse it. Stepped wear or hardened rubber would be a no-go, but I’ve rarely seen that.

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I think side leaks cause more problems. We’ll replace this O-ring to be safe.

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We’ll adjust it with the TMR settings.

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I’ll check it by eye, lift the float with my finger to verify, and only assemble once I’m satisfied.
With fuel flowing through in this condition, we’re good. I’ve installed a fuel filter as a precaution.
We might need to coat it down the road. After that, a test ride and we’re done.

 

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