Manual - Chapter 1 Engine

4. Removing the engine unit from the frame

Note: It is possible to separate the engine unit from the transmission at the bellhousing rear face and to remove the engine unit after the gearbox and final drive have first been withdrawn. (The engine cannot be removed on its own. leaving the gearbox and transmission attached to the frame, since this leads to an unacceptable risk of damage and a great deal of difficultly in aligning the clutch and gearbox input shaft and the engine mountings.) Since, however, the above method involves a great deal of care in aligning the gearbox input shaft and clutch release with the clutch and in supporting solidly the frame, engine and transmission components as they are separated, it is recommended that the engine and transmission are removed from the frame as a single unit and then separated,- the following instructions are based on this procedure. Owners who do not wish to use the recommended method should note that procedures are similar until the final stages. Refer to Chapter3 - Gearbox for more information.

  1. Place the machine firmly on its center stand so that it is standing securely and there is no likelihood that it may fail over. This is extremely important as owing to the weight of the complete machine and the engine, any instability during dismantling will probably be uncontrollable. lf possible, place the machine on a raised platform. This will improve accessibility and ease engine removal. Again, owing to the weight of the machine, ensure that the platform is sufficiently strong and well supported.
  2. Drain the engine oil and remove the oil filter, as described in Minor Service - Oil change.
  3. On Kl00 RS, Kl00RT and Kl00LT models it should suffice to remove only the fairing knee pads and lower sections (side panels and radiator cover); owners may, however, feel it preferable to eliminate any risk of damage by removing the entire fairing. On K75 S models it is best to remove the fairing. Where fitted, remove also the engine spoiler or belly fairing. Refer to Chapter 7 - Frame & Forks.
  4. On all models, lift the seat, remove both side panels, remove the radiator cover panels (where fitted), then remove the fuel tank as described in Chapter 5 - Fuel & Oil.
  5. Note that whenever any component is moved, all mounting nuts, bolts, or screws should be refitted in their original locations with their respective washers and mounting rubbers and/or spacers.
  6. Disconnect and remove the fuel injection control unit and storage tray, as described in Chapter 5 - Fuel & Oil.
  7. Remove the battery as described in Routine Maintenance and tie the coolant expansion tank to the frame out of harm's way.
  8. Remove the air intake hose.
  9. Working as described in Chapter 4 - Cooling, drain the coolant, disconnect the radiator hoses (pull the bottom hose out of the crankcase cover) and remove the radiator.
  10. Remove the exhaust system. See Chapter 5 - Fuel & Oil.
  11. Remove the alternator cover, ignition HT coil cover, number plate bracket and the rear mudguard.
  12. Working as described in Routine Maintenance, disconnect and remove clear of the engine/transmission the throttle, choke and clutch cables.
  13. Working methodically round the machine, disconnect all electrical wires joining the engine/transmission unit to the frame. Trace each wire from the component concerned up to the connector joining it to the main wiring loom and separate the connector; noting where each is installed. Remove the clamps or cable ties securing the wire to the frame. These wires include the alternator connector plug, the starter motor cable, the ignition HT coil low-tension wires (make a written note of exactly what color wire is fitted to which terminal), the frame earth connection (retained by a single nut and bolt to the left-hand side of the frame top tubes, at the rear of the steering head), the speedometer impulse transmitter, the stop lamp rear switch, the gear position indicator switch, the oil pressure switch, the ignition trigger assembly, the choke warning lamp switch and the engine wiring harness. Be very careful to check that all wires are released and are positioned so that they will not hinder the removal of the frame from the engine/transmission unit.
  14. Slacken the two engine front mounting nuts and the bolts securing the bellhousing/frame joint and the two gearbox/frame joints; also the rear suspension bottom mounting nut. lf any fastener is difficult to move, apply a good quantity of penetrating fluid and allow time for it to work before proceeding further. In the case of the front mounting bolts, slacken the nuts and attempt to break the bolts free by rotating them before attempting to tap them out. Make a final check that all components have been disconnected or removed which might hinder the removal of the frame from the engine/transmission unit; the unit should now be held only by its six mountings.
  15. Enlist the aid of two or three assistants to withdraw the frame; one to 'steer' the front forks, another to lift the back of the frame and a third to help with the engine/transmission unit.
  16. Place blocks of wood or similar under the sump so that the engine is securely supported and cannot fail. Place another block of wood or similar support under the final drive case; the support should be tail enough to fit closely under the casing.
  17. Remove the rear suspension unit from its bottom mounting and lower the final drive case on to its support; do not allow the swinging arm to move too far downwards or the gaiter at its front end may be torn and never allow it to drop or it may crack the casing.
  18. With the assistants standing ready, unscrew and remove the bellhousing mounting bolt, the engine front mountings and the gearbox mounting bolts; note carefully the presence and number of any shims that may be found at any of the mountings. The engine/transmission unit should now be supported securely on its sump support, on the center stand and on the rear wheel/final drive support.
  19. Taking care not to scratch the paintwork or damage any component, carefully lift the frame at the rear and walk it forwards clear of the engine and transmission.
  20. On Kl00 RS, Kl00RT and Kl00LT models check the engine front mounting rubber bushes for cracks, splits, perishing or compaction and renew them if they show any sign of deterioration or damage.

4.11 Ignition HT coil cover is retained by four Allen screws - 100 models

4.13a Make a written note of connections before disconnecting ignition HT coil leads

4.13b Check that all wires are disconnected between engine/transmission and frame - note speedometer transmitter wires .........

4.13c ..... and ignition trigger assembly wires

4.13d Coolant temperature sensor connector is secured by a wire clip