{"id":56678,"date":"2016-06-23T20:19:02","date_gmt":"2016-06-23T11:19:02","guid":{"rendered":"https:\/\/www.decoboco.info\/en\/?p=56678"},"modified":"2026-09-24T13:44:50","modified_gmt":"2026-09-24T04:44:50","slug":"gsxr1100k-deco-mainte-engine-cover-broken-bolt-removal-2","status":"publish","type":"post","link":"https:\/\/www.decoboco.info\/en\/20160623\/everyday-events\/gsxr1100k-deco-mainte-engine-cover-broken-bolt-removal-2","title":{"rendered":"GSX-R1100K Deco-mainte: Engine cover broken bolt removal"},"content":{"rendered":"

\"DSC_0982\"
\nDuring a test ride, I noticed the shift was sluggish and not engaging cleanly. Let’s check all the components.<\/p>\n

<\/p>\n

\"P1610107\"
\nMy first suspicion was the clutch release piston marks. Due to the offset sprocket setup, the piston cover wasn’t installed, so the piston likely made contact when the clutch was disengaged.
\nThe clutch engagement felt responsive, so I initially figured the chain was making contact and preventing full disengagement. I ground down the contact point.<\/p>\n

\"P1610110\"
\nIt’s a bit of a hack, but I worked with what was on hand. For now, it’s better to keep costs down and move forward with the repair.<\/p>\n

\"P1610104\"
\nThis area also had chain contact, so I ground it down and sank it about 2 mm.<\/p>\n

\"P1610105\"
\nThe inside was polished, so it came out nice and clean.<\/p>\n

\"P1610106\"
\nThe cup looks new, so I reused it.
\nSince there was no improvement at all, I thought, “What’s going on?” and decided to focus on the clutch for further investigation.<\/p>\n

\"P1610144\" \"P1610143\"
\nThe friction plate material is flaking off like crazy. It’s pretty bad. Has it never been replaced since the model year?<\/p>\n

\"P1610144\"
\nSteel on steel\u2014it might actually be a pretty aggressive friction setup.<\/p>\n

\"_1610146\" \"_1610145\"
\nNaturally, it’s all caked with debris.<\/p>\n

\"_1610149\" \"_1610147\"
\nThe basket itself is in good condition, so I was relieved.<\/p>\n

\"DSC_0984_1\"
\nA lock nut also serves the purpose of a lock washer.<\/p>\n

GSX-R models from this era don’t use lock nuts, so I was a bit concerned. The 1200-series lock nut doesn’t grip well on the GSX-R standard washer, so the engagement becomes shallow. I sourced this thinner washer instead. The outer diameter doesn’t match for installation, so I’ll punch it out and adjust the outer diameter to fit.<\/p>\n

\"_1610151\" \"_1610152\"
\nThere’s so little material that bending it is a real pain. Well, next time I’ll just install it without bending.
\nThe clutch now engages cleanly and the shift is smooth, but now it’s slowly overflowing… This is frustrating.<\/p>\n

 <\/p>\n

 <\/p>\n","protected":false},"excerpt":{"rendered":"

During a test ride, I noticed the shift was sluggish and not engaging cleanly. Let’s check all the components.<\/p>\n","protected":false},"author":2,"featured_media":56663,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"pochipp_cv_data":"","swell_btn_cv_data":"","footnotes":""},"categories":[1924],"tags":[123,91],"class_list":["post-56678","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-everyday-events","tag-deco-mainte","tag-gv73a"],"_links":{"self":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts\/56678","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/comments?post=56678"}],"version-history":[{"count":0,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts\/56678\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/media\/56663"}],"wp:attachment":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/media?parent=56678"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/categories?post=56678"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/tags?post=56678"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}