9. Dismantling the engine unit: removing the cylinder head
If the engine is in the frame a large amount of preliminary
dismantling is necessary before the head can be removed. Proceed as
follows, referring to Section 4 - Removing engine unit from the frame of this Chapter for information on the full procedures
On Kl00 RS, Kl00 RT and Kl00 LT models remove the fairing kneepads and
lower side sections and radiator cover. On K75 S models, owners may wish
to gain additional working space by removing the fairing. The engine
spoiler or belly fairing and the radiator cover panels (where fitted)
must be removed. Lift the seat, remove both side panels and disconnect
the battery (negative terminal first) then remove the fuel tank and the
Remove the air intake hose; drain the cooling system and disconnect
the radiator bottom hose. Remove the ignition HT coil cover and
disconnect the throttle and choke cables.
Slacken the intake stub clips and the clips at the plenum chamber ends
of the crankcase breather and air filter hoses. Disconnect the fuel rail
hoses and the fuel injector wires, also all electrical leads from
components on the throttle body assembly.
Noting that it may be necessary to gain extra working space by
removing the air filter top and the element, carefully withdraw the
plenum chamber/throttle body assembly, ensuring that all control
cables and electrical leads are disconnected, also the fuel and vacuum
hoses from the pressure regulator.
Disconnect the radiator top hose. The coolant and intake stubs and the
fuel rail and injectors need only be removed, if required. Remove the HT
leads and spark plugs.
Referring to Sections 6 and Section 8 of this Chapter, remove the engine outer covers and the camshafts and cam chain components.
Check that all components have been removed or disconnected which will
prevent the lifting of the cylinder head, then remove the engine front
left-hand mounting bolt and nut, noting the presence and number of any
shims which might be fitted.
Working in a diagonal sequence from the outside inwards, progressively
and evenly slacken the cylinder head bolts and then remove them with
their washers; there are 8 bolts on 75 models, ten on 100 models.
Tap the head firmly at a suitably-reinforced point to break the seal
without risking damage and withdraw it.
Peel off the gasket and discard it. Note the two locating dowels;
unless firmly fixed in the cylinder block these should be removed and