6. Dismantling the engine unit: removing the outer covers
While specific instructions are given below for each cover, the
following general notes apply to all.
Since all are well above the level of oil there is no need to drain the engine
oil before removing any of these covers but be prepared to mop up or
catch the small] amount of on that will be released as the cover is removed.
Wipe off all traces of dirt from around the cover before removing it, so
that nothing drops into the engine.
Take care not to stretch or damage the rubber seals fitted to the cylinder
head and crankcase covers; these can be re-used many times if they are
Always slacken screws by a turn at a time, working in a diagonal sequence
from the outside inwards. When all pressure is released, remove the
screws, tap the cover lightly once or twice with a soft-faced mallet to
break the seal and pull the cover away.
On early Kl00 and Kl00 RS models remove the two drain plugs screwed
into the cover and place the machine on its side stand so that any oil
remaining in the cover can drip out. On all other models be prepared to
catch the residual oil as the cover is removed.
Remove the ten (75 models) or twelve (100 models) bolts securing the
cover and withdraw it, noting the presence of the coil spring fitted to
one of the camshaft bearing caps. Mop up any spilt oil; do not allow
oil flow into the spark plug channel.
Crankshaft (engine right-hand) cover
On Kl00 RS, Kl00 RT and Kl00 LT models remove the fairing right-hand
knee pad, lower side section and radiator cover. Where fitted, remove
the engine spoiler or belly fairing and the radiator cover panels. See
Chapter 7 Frame & Forks.
Drain the coolant if not already done, then disconnect and remove the
radiator bottom hose. See
Chapter 4 - Cooling.
Remove the eight (75 models) or ten (100 models) bolts securing the
cover and withdraw it.
Cam chain (engine front) cover
It is possible to remove this cover after merely slackening the crankshaft
cover bolts and removing the two cylinder head cover front bolts;
however this is not recommended as it is not possible to clean the
sealing surfaces well enough to guarantee a leak-free joint on reassembly.
Start by removing both engine side covers as described in paragraphs
Disconnect the oil pressure switch wire and feed it downwards clear of
the front cover, releasing the metal securing clips. Remove the horn (75
Remove the cover retaining screws and withdraw the cover noting the
two gaskets, one along each mating surface, and the two locating dowels
set in the top mating surface. Always renew the gaskets to prevent