Manual - Chapter 1 Engine

5. Dismantling the engine unit: preliminaries and general procedures

Preliminary dismantling

  1. If the engine/transmission unit has been removed as a single unit withdraw the alternator and starter motor (see Chapter 10 - Electrical) and separate the gearbox and final drive (see Chapter 3 - Gearbox) from the bellhousing, noting that it will be necessary to remove the stand assembly to reach the two lowest gearbox/bellhousing retaining screws. There is no need to separate the final drive from the gearbox. Dismantle the clutch as described in Chapter 2 - Clutch.
  2. As described in Chapter 5 - Fuel & Oil, remove the top half of the air filter assembly with the engine wiring harness attached to it, disconnect the loom from all other electrical components. Withdraw the air filter element end the air cleaner bottom half, the fuel rail and injectors, the plenum chamber and crankcase breather, the throttle bodies and intake stubs end the EECS pressure relief valve end hoses (where fitted).
  3. Remove the coolant hose stub. See Chapter 4 - Cooling.
  4. Remove the ignition HT coils, noting carefully where the HT leads are connected, see Chapter 6 - Ignition. Remove the spark plugs and HT leads as described in Maintenance - Minor Service- Spark plugs check.
  5. If necessary, remove the sump (oil pan) and pump pick-up as described in Chapter 5, and remove the oil/water pump assembly as described in Chapters 4 and 5.
  6. Remove the ignition trigger assembly as described in Chapter 6 - Ignition.

General procedures

  1. If any of the following operations are to be carried out with the main cylinder block still in the frame, ensure that the machine is supported firmly on the center stand. It is less tiring if the machine can be raised off the ground on a strong, low, bench. Have blocks to hand for supporting the rear of the machine, especially if the rear wheel is to be removed.
  2. Before commencing any work involving the electrical system, disconnect the battery negative (earth) lead at the terminal to prevent any risk of short circuits.
  3. On Kl00 RS, Kl00 RT and Kl00 LT models it will usually be necessary to remove the fairing knee pads and lower sections (side panels and radiator cover) to gain adequate access to components, refer to Chapter 7 for full details. The complete fairing can be removed to eliminate any risk of damage, if required. Where fitted, remove the belly fairing or engine spoiler. See Chapter 7 -Frame & Forks.
  4. Before any dismantling work is undertaken, the external surfaces of the unit should be thoroughly cleaned and degreased. This will prevent the contamination of the engine internals, and will also make working a lot easier and cleaner. A high flash-point solvent, such as paraffin (kerosene) can be used, or better still, a proprietary engine degreaser such as Gunk. Use old paintbrushes and toothbrushes to work the solvent into the various recesses of the engine castings. Take care to exclude solvent or water from the electrical components and intake and exhaust ports. The use of petrol (gasoline) as a cleaning medium should be avoided, because the vapour is explosive and can be toxic if used in a confined space.
  5. When clean and dry, arrange the unit on the workbench, leaving a suitable clear area for working. Gather a selection of small containers and plastic bags so that parts can be grouped together in an easily identifiable manner. Some paper and a pen should be on hand to permit notes to be made and labels attached where necessary. A supply of clean rag is also required.
  6. Before commencing work, read through the appropriate section so that some idea of the necessary procedure can be gained. When removing the various engine components great force is seldom required, unless specified. In many cases, a component's reluctance to be removed is indicative of an incorrect approach or removal method. lf in any doubt, re-check with the text.
  7. Note: All descriptions of locations ie left, right, front and rear refer to components as they would he if installed in the machine with the rider normally seated. Given the potential for confusion with this engine design the terms 'top end' and 'bottom end', referring respectively to the cylinder head and crankshaft assemblies, have been avoided if at all possible. However in some unavoidable cases, mention has been made of 'upper' or 'lower' components,- these refer to the upper side, ie the intake side or top surface of the engine or to the lower side, ie the exhaust side or underneath (sump/oil pan) of the engine. Bear this in mind at all times, but particularly if the engine is supported in some unusual position on the workbench.