Honda ST1100 Pan European engine removal and strip

[@YKB6.9]

Where have ya been buddy... Thanks for saving my life today.

[@snottyvar]

You are the Bob Ross of mechanical engineering. It is impossible to be in a bad mood watching your fantastic videos. All the best

[@GMCBigBlock420]

Some of the greatest things in the world come from skilled men in the most humble of sheds. A monument to blokes everywhere!!

[@marscruz]

You may have already found the source of the problem in the oil pickup tube o-ring seal misassembly. Sucking up air with the oil could easily cause low oil pressure and big end bearing wear. Your determination to find the problem is admirable and inspiring. She will be better than new when you're done with her.

[@AllenMillyard]

I’ve just received a big box of nos parts and gaskets 🙂

[@liver.flush.maestro]

@@AllenMillyard Yay! I am looking for your next video 🙂 No cup cakes during Christmas?

[@drewmarshall4422]

@@AllenMillyard Cant wait for pt 2!!

[@noelcastle3986]

Great teardown video looking forward to part 2 .

[@yourealwaysright6770]

Surely you’d expect some cavitation marks on the oil pump if that was the case

[@lennartswenson2690]

I watch a lot of wristwatch repair videos and this reminds me those videos, lots of parts and fasteners only larger. Just like a disassembled wristwatch, it boggles my mind how this man can remember where everything goes in reassembly!...

[@mickralph4623]

I would watch you rebuild/fix/build/radically change just about anything! Absolutely first class stuff. Happy holidays and a brilliant 2023 to you and your family. Many thanks mate!

[@keyboarddancers7751]

Agreed. I would happily watch Mr Millyard taking apart a three pin plug!

[@menom7]

Agreed also!!!

[@beowulf5982]

Agree 100%

[@Cupat1]

"Happy holidays" Merry Christmas you mean

[@mattthomson1689]

Must watch the remaining sections, even though my road experience on my 2004 ST 1300 is minimal, just now finishing up major maintenance on everything except major engine work. Thanks for the wonderful presentation!

[@ResidentNetizen]

Allen makes it look so easy to pull the motor out of the frame. I wonder why people prefer instead to pull the whole back of the bike apart to get at a bad alternator- and still fight their way though it. Always a pleasure to see the work around Millyard's place!

[@cristian6766]

When i was a kid in elementary school, i used to skip first class to watch Mark Evans on his builds on tv, I only wish i could skip work to watch your builds.

[@Jodyrides]

I was a Honda motorcycle dealer mechanic in the 70s. The bulletin came from Japan from Honda to the service departments of the dealers here in the USA. when installing dry paper gaskets, get a can of rust, oleum, silver aluminum paint. Do not stir or shake the can. Scrape the thick paint from the bottom of the can and apply that to the new gasket both sides. When the area the gasket is going to be installed on is clean., install that gasket wet. That gasket should never leak, and, it will come off in one piece at the next disassembly… I bought a quart of that rust oleum silver aluminum paint back in the 70s. I have been using it ever since on my dry gaskets such as, my valve, cover gaskets on my moto Guzzis.. anytime I have a dry gasket, I apply that thick gout from the bottom of that paint can to the gasket and I put it on still wet.. I have never had to scrape those treated gaskets or buy a replacement gasket, such as on my moto guzzi valve cover gaskets since.. I just had to be careful on engines that were anodized black that I didn’t use too much of the aluminum paint that would cause a run .. I appreciate your meticulous video. Doing the video and the work must have increased the time it took by 90%. any time you have an oil pump out or a new pump to install. It is a good idea to pack it solid with petroleum jelly to prevent initial start up oil starvation..i learned that from a long time factory schooled saab dealer mechanic..

[@AllenMillyard]

I always crank the engine on the starter with no ignition until the oil light goes out this ensures the oil pump is primed before the engine is started

[@derkarhu5079]

to help with the engine removal, i use a couple of the "windbag" inflatable cushion things that you get from. DIY, or online, on top of the wooden blocks...you inflate them, to take the engine weight, which makes removing mounting bolts a charm, then, with the bolts out, you can slowly deflate the bags; because they are 'soft', you can wiggle the engine about, as needed, while lowering it. when the bags are fully deflated, you can drag them out by wiggling the engine a bit. This makes reassembly a charm, too, since the air bags give you 'microscopic' control of the engine as it comes up to the correct position!

[@brad4908]

I had a ‘99 for 10 years and did 173000 miles. Best bike i’ve ever owned. Most epic experience was spending the night in a Polish petrol station car park stripping down and rebuilding the cooling system by the torch light of the most awesome driver (who spoke no English). Turned out the system was fine and the temperature gauge was just grounding out. The most user-serviceable (big) bike I’ve ever owned

[@brandogeberbin7563]

The only thing i had to replace on my honda's all 8 of them, Clutches, Timing chain tensioners, and adjust valves when needed. And all 8 have seen track time, racing, daily driving, Street racing. A st1100, Valve adjustments, clutches, timing belt tensioner. Check gear lash on drive shaft. I have never torn a honda engine apart! I have abused my honda's from day 1 from the honda dealer. I am the only one in all of his customers that has a new bike and hit 190 miles an hour in the first 5 minutes after purchasing the bike with zero miles on it. Each of my honda's had minimum of 40 thousand miles. My 1100 blackbirds had 65 thousand miles each and top speed radared on the track 198mph. Even my moms 1964 honda 50 still runs, and my dads 1970 350 twin, motors have never been torn down.

[@nightster6378]

Happy Christmas to you and your family and thank you for the entertainment you give us, this was unexpected and will get to watch it later. I can imagine you sitting down to a plate full of "turkey and stuffing cupcakes". Have a great day and to those who support you.

[@malcellison8831]

Superb work, Allen. You’re such a modest guy despite your top level mechanical skills. Thanks for posting this video: looking forward to part two 😊

[@1924ab]

Those sure are sweet bikes, had a customer who always brought his ST1300 to service and I always thanked him for coming in because I loved to take it for its test ride.

[@jhellnowh]

You are a legend Allen. I wish I had the tiniest percentage of your skills. I’m struggling with a crf250l engine and you’re doing your thing. Amazing!

[@rrAinierr]

in the exact same boat as you, friend

[@lazyeejay]

Alan you're a genius. I know nothing about mechanical engineering (I'm the type who opens a car bonnet and just stares blankly at the engine lol) but watching someone who is so clever at what they do is fascinating.

[@N1gel]

How can you produce a video without taking a cupcake? But hats off to Tracy. Putting a titanium valve on the Christmas tree was a show of real appreciation and understanding for her husband. Great. Have a great......... rebuild

[@mrthomas394]

This guy has got to be the greatest mechanic ever. My skills are basically doing a service and changing brake pads... I'd give a kidney to have 50% of his knowledge and skills

[@108padma]

As a '99 owner (~180,000 km, no problems, even considering the fact that maintenance has been sonewhat sketchy - a testament to the brilliance of Honda) I'm gobsmacked at your fastidiousness, Alan. It's a revelation to me to see 'my' engine being taken apart. I really wish I could have you do a restoration on my 'old girl', to keep her running at her best for another 25 years. My sincere salutations from Perth, Australia.

[@andybobandy641]

If anyone needs an hour long video for every single entry, it is you my friend!

[@TheMegaross91]

I lunched the gearbox on my tiger 1050 Saturday. This video has been invaluable in giving me an idea of where to go with dropping, replacing temporarily and hopefully fixing the original engine.

[@ian-c.01]

A low mileage Honda with engine knocking is almost unheard of but I'm sure you'll figure it out and fix it ! I have to say it's a real pleasure to see the insides of that engine, it looks fantastically well thought out and well built ! Having the gearbox come out all in one like that is genius and really simplifies the reassembly ! Looking forward to seeing the job progress !

[@AllenMillyard]

To be fair it ran and rode really well I did 1200 miles in a month but the knocking when pulling away was anoying me so I thought why not strip it 🙂

[@CitizenSmith50]

My first Honda was a 1962 CA77 305cc Dream, which was simplicity itself to work on. It's mindboggling to see how much technology and design changed in the ensuing 40 years! Thanks for the great video.

[@tonymarkey6525]

I don’t own a Pan, I never will. I have no need to watch this and yet the power of Millyard means I am riveted and looking forward with much expectation and excitement to episode 2. Great to have your vids back on Mr M. A wonderful tonic for a dreary Winter’s night!🙂🙂👍👍

[@drdoolittle5724]

What more can one ask for, Mr Millyard spreading peace and absolute calm, whilst I wait for erindoors to get a move on and get the feast prepared! She said we are having some lidle spiky pork road kill picked up last night after the carol service!

[@neillambton4065]

Great video Allan, and great to see you and your good lady helping some of of our most wonderful wildlife, the much threatened Hedgehogs. Fantastic little creatures. We have a hedgehog house in our front garden, but have`nt seen any hedgehogs for some years now.

[@stephenpotts8170]

Merry Christmas Allen, thank you for all the entertainment you give to us mere mortals, I have stripped down a few bikes over the years, but that pan would be a step to far for me, I don't know how you do it. Bloody marvellous. thank you.

[@Oldbmwr100rs]

Watching this reminds me of tearing down and repairing the gearbox of my 1975 gold wing. In fact it seems Honda kept a lot of their designs from that old bike through their other larger bikes. The ST motor reminds me far too much of the old CX5oo, but just going from pushrods to belt driven OHC. I feel a sense of dread when I have to go into jobs like this, but really as I start digging in, time passes and it's usually easier than I imagined it would be, and I chew right through it.

[@rosegold-beats]

my lazyness would never let me seek a problem this way, its good that you are so thorough

[@siem8160]

With Allen, an engine removal becomes an open-heart and total rebuilt operation. As usual it's perfect with funs sequences.

[@Supernaut2000]

Gosh I doubt any dealer in the world has taken apart the engine from an ST-1100! Amazing to see, simple and yet so well engineered to provide so many miles of enjoyment.

[@TwoUpTourer]

I had an ST1100, and stripped it down to the chassis once to get the chassis alignment checked. I was not game to take the engine out, and youv'e confirmed I made the right decision! The engine on these is bullet proof, so yours must be one of the very few that's been pulled apart.

[@gvillxtine2773]

Thank you so much Allen. As someone who's always had an interest in motorcycle mechanics, but never knew where to start because it seems so daunting, your videos are truly inspiring to me. Take Care!

[@paulemmink4303]

DITTO!!!!

[@zennor_man]

Allen you are a genius…I have never owned or even ridden a motorcycle but your channel is required viewing for me…thanks 🦔🦔🦔

[@minnesotatomcat]

I’ve always loved Honda, everything always seems very well made and well thought out. It’s like Allen was an engineer for Honda or something! Great vid 👍

[@johnlang3233]

Great video - I've had 9 of these ST1100s & never had any engine issues - looking forward to part 2

[@kevinchamberlain7928]

I must say, Alan, of every single bike engine I've looked inside, in this model clearly Honda have thrown all their prowess, pride and skill into! Fabulous engine! It's got me thinking...

[@wetleyrocks3092]

When you revealed your compassion for hedgehogs you won me over, finally subscribed!

[@ybliga]

I owned a 98 Pan and although now sold and replaced . . .I'm watching with much fascination!!!!

[@gazzafloss]

The ST 1100 was a rock solid reliable unit, engine failures, if any were rare. A mate I used to ride with had one with more than 200,000 trouble free klms on it. Good old Honda reliability.

[@bernibeckmann9753]

I love the dichotomy of removing and reassembling very complex systems and having outlined tool holders lest you put one in the wrong spot. Cheers.

[@UnclePhilST1100]

Allen - You may or may not see this but I'll post it anyway. I own 8 ST1100s of various years - 4 runners and 4 parts bikes. Between the 4 runners, I have over 470,000 miles in the seats of ST1100s (hoping to cross the 1/2 million mile mark next year). I have found myself having to swap engines twice - once because of a premature water pump failure at 139,000 miles and the second time it appears to be an oil ring failure (haven't dug into it yet but the engine smokes oil pretty badly, oil in the headers, etc.) at 45,000 miles on that engine. What I have found is if you remove the alternator before the final engine removal, it eliminates a lot of the 'wrestling' to get the engine out. Once you lower the engine a little bit, you can get to all three alternator bolts. And if you can keep the alternator 'gear' assembly into the engine and just remove the base alternator it becomes even easier. I found the issue was the alternator wants to hang on the gear shift 'ear' on the frame even after the lever is removed and the frame 'ear' on the left side at the right back gets in the way. I hope you don't have to remove another ST1100 engine but if you do, here's an idea that might be of some help to you. Your videos on ST1100s are top notch and are very helpful to me. BTW, I've ridden in your fair land many times and always enjoyed it (multiple write-ups on my website). I've even ridden Hard Knott Pass on a rental ST1300. 'Uncle' Phil Derryberry

[@stewartellinson8846]

Excellent stuff. Possibly the only person ever to strip an ST1100 engine since haynes! the pickup O ring issue seems to show how a small problem can cause a much bigger one.

[@philw4053]

Love the way you just rip these things apart and everything is so organised. I'd be dropping / losing bits, coming up against things that just wouldn't budge, then when the suddenly gave way and launched themselves into the air trying to remember did that go this way around or that way around..... You make it all look so easy! Thanks - a great episode and really looking forward to finding out where that gearbox / engine noise was coming from.

[@rdaystrom4540]

I'm thrilled to watch you tackle this massive project. Your skills are off the charts. Love your explanations and the narration is awesome.

[@Import61]

You have inspired me to start a motorcycle mechanic apprenticeship at a classic and vintage motorcycle workshop! Only a matter of time before I start adding extra cylinders to engines :)

[@AllenMillyard]

That’s brilliant

[@JR-bj3uf]

What's amazing is a machine so complex is, at the same time, one of the most reliable bikes in the world.

[@andysmith3730]

For someone who refers to the owners manual even for adjusting a chain, your videos are awesome. What a glorious engine for so comparative little

[@shadowred1980]

Thank you for making the content throughout the year, all the best for 2023.

[@Hertog_von_Berkshire]

Thanks Allen, video is a great Christmas present to all your fans. Working on the Honda has got to be far more rewarding than fixing nicknacks in Henry's back garden. 😁

[@ridethroughlifertl]

I've had a lot of motorcycles and my 95 ST1100 was one of my all-time favorites. It's such a great bike for long-distance travel.

[@garrycoates2147]

I am really going to enjoy this breakdown as I have a 1995 model. I have owned it since new and its still going strong.

[@MattysWorkshop]

Merry Christmas and all the best for 2023 to all, thank you for all the content throughout the year, cheers

[@MegaPoxie]

The 1st main problem I can see is it doesn't have enough cylinders, maybe another 4 need to be added! Great content as usual.

[@eleuterioramalho6897]

his work is incredible, namely the construction of a six-cylinder engine from a four-cylinder engine, incredible! I'm a mechanical engineer and I can never do that, nor the idea of ​​doing it.

[@mrtopcat2]

I enjoyed the video. Very nice work indeed. For stubborn gasket removal, I have tested a wonderful method that I like to share. It worked like a charm. I have used a multi tool with the common triangular velcro sanding attachment adapter and then attached green kitchen scotch brush pads to it, which I cut to small square sizes. I greased those with some transmission assembly lube, so that they do not create or shed any particles. I needed new pads every few inches as the pads would load up and lose abrasiveness. No problem, they are available plentiful and cheap enough. I was able to rotate the scotch brush pads 180 as well, so each pad got 2x passes. It worked like wonder. Fast efficient and so free of abrasive particles, that I probably could have even skipped covering the adjacent parts. I have appointed this method from now on to be my preferred method for removing gaskets. It sure beat any rotational tool method with the corresponding flinging off of grease.

[@enhancesoutheast5964]

Thanks Santa..A new vid from AM... My reward for being a good lad in 2022 . A happy Christmas and new year to Alan and family from everybody who loves his work.. 👍🎅

[@martinjames9250]

WOW! 😮 When I remember the pressure I felt when replacing the belt and ancillaries on one of mine! This blows me away! --- Excellent bikes those. 👍

[@ukurtlele1494]

Wow, what a load of engineering. I wonder how many people were involved with designing just the engine. It's a good thing you are re-assembling this. My memory isn't what it used to be. Thanks for the holiday video! It's just perfect.

[@kiwizz2177]

Wish I had 10% of the knowledge Allen has and the guts to pull an engine apart. ! Allen’s just an amazing mechanic !

[@490Believer]

Allen makes all he does look so easy. I wish he was nearer me so he could service my 1986 Honda VF1100c V65 Magna.

[@carleddison7479]

Great Christmas viewing. Watching a mechanical genius at work is much better than anything on TV.

[@lightningbolt5775]

Allen, Glad you have chosen the Pan as your winter hack, I too possess one myself ... look forward to the big end investigation. I am also a fan of "Shed and Buried" starring Henry Cole, Skid and your good self. Fantastic!

[@chrv2956]

I am drivning a ST1100 my self. I love to see it inside and the good condition is is in. As always I appreciate to see how carefull you are doing everything, and how you deal with all details. A true pleasure. Mary christmas to you and your family from Denmark

[@GT380man]

A testament to Honda’s bike design & manufacturing that you can buy a 22 year old bike and find, in the main, absolutely nothing wrong with it. It’s a helluva biker isn’t it? A friend had a Yamaha FJR1300 & that had the same kind of well-madman bulletproof feel to it all. It was bloody heavy, though my pal said the reward is that it feels completely planted at any speed. Much loved by some police bikers. Another pal has had a few Pans and absolutely swears by them. Huge mileage fellow, he does a long, European mainland holiday tour each year. I find I no longer want to ride in the rain, though I did three wet days a couple of summers back and it wasn’t a problem. Less slippery than I’d remembered though again I wonder if the weight of it was a plus (Suzuki GSX1400). Enjoy your Pan, Allen!

[@s8rut]

Most enjoyable thing I have seen over Christmas! Best wishes for 2023.

[@beezaman]

Great video always wondered what was under those plastic bits. Had mine 2001 for 17 years hope I never have to do what you've just done. Look forward to part 2.

[@internetpolification]

It looks terrifying to me!

[@Axel_Andersen]

The cinematography and story telling just keeps getting better. NIce.

[@martinholt2844]

You continue to amaze me how easily you strip this down and fully understand all the different intricacies of the manufacturers engines, not just one brand, but pretty much all of them. I’m on awe and plucking up the courage to strip my DT250 engine down soon and I don’t think you can get much simpler! Great stuff Allen! 👍

[@mshort7087]

I salute you, Sir. I’d would never get that bike back together. Thanks for bringing us along

[@NoBoW73]

Great video as always Allen. Your patience is admirable for sure. I’ve learned so much from you. That you don’t have to have a big fancy shop and tools to do the work you enjoy. I started working on my 800 Vulcan after finding your channel a few months ago. Now I have started my own channel. My first video is about my Nissan pickup. You are such an inspiration!! Merry Christmas from Kentucky to you and your family!!

[@julianpritchard2558]

Nice to have you back.

[@gerryjamesedwards1227]

An AM video on Christmas Day is the best present.

[@richardscovell6620]

It reminds me of the Allan Partridge sketch where he takes a perfectly ok trouser press to bits with no idea how to reassemble it...however, I've every confidence your ST will go back together better than Mr Honda could...happy new year

[@RichardGumbrell]

Allen, I shall be following this series closely. Thanks for the time and effort you put into making these videos.

[@andyt4198]

Marvellous engineering as usual Alan. As someone has said I wish I had even a small percentage of you knowledge and skills. Keep up the good work.

[@stephenrice4554]

Superb as ever . The value of demonstration is immeasurable . Great video 👍🇬🇧

[@134StormShadow]

Thanks Alan, just the inspiration I needed to get my bike engine apart and investigate the knocking noise (when cold). Fisrt thing I'm checking is that oil pickup O ring. Mind you, after 468k miles and 5 cambelts somethings bound to be a tad worn. 😉

[@doctordapp]

Woohoo, a new video from the mechanic master himself! And I am the first to enjoy it! Merry Christmas you all! 🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄

[@chrishunter5041]

All the best for 2023👍

[@dalehawkes1698]

Thanks for the video , just perfect for my Christmas Day evening ,there’s something mesmerising about watching a pro dissemble an engine. Thanks again 🎉

[@plunder1956]

As ever a pleasure to watch your meticulous working. So far this engine seems to be in superb condition apart from that one seal. The Pan's reputation is intact.

[@AllenMillyard]

I think ive got the only one with an engine problem but ill fix it

[@plunder1956]

@@AllenMillyard that oil seal seems a minor issue, could that be enough? Otherwise everything looks fairly almost new 👍 16k for a Pan is almost run in.

[@gs1100ed]

@@plunder1956 that improperly installed oil seal can likely cause bearing issues

[@deancoley7987]

Like a giant jigsaw, in another life I think Allen must have been a top surgeon. Amazing video and description work. KZbin and Allen are a perfect match to which the engineering world can enjoy and share

[@mickwalker8813]

But he would have to work with the "engine" running!

[@arlandgaylor]

ALLEN!!!!!! if I ever get to do the much wanting to ride the UK and France id love to just stop in and have a Tea with you... Much love from Austin Texas. can't wait for the rest of your ST build.... Thank you for taking the time to share with us, love the hedgehogs.....

[@kerrygleeson4409]

See you in 2023 Allen thanks for sharing

[@mrsmith4662]

What a huge big complex lump. I'd forgotten Honda had made such a machine. This is going to be a fascinating project and good luck putting this 1000 piece jigsaw puzzle back together again when fixed.

[@carleddison7479]

Ahem, there'll be no luck involved.

[@cristian6766]

Mr. Allen, I know you are a savant when it comes to disassembling, assembling, modifying and fabricating parts and motorcycles, but, how do you know where all bolts and nuts come from when putting your amazing and wonderful machines back together without using bags or something similar? Love the channel! All the best from 🇷🇴!

[@AllenMillyard]

I just remember where everything goes

[@RussellRF900Rrv]

You are the main man many thanks for being the sane person in a mad mad mad world & showing us inside our st1100 pan

[@peterdoe2617]

Whata pleasure! It is, to watch you work on an engine. A michelin star mechanic, if there was such! Have a great holiday season!

[@simonthomas5367]

This is great stuff Alan! Really interesting, detailed and well filmed, as always. I picked up my '98 Pan European in October. Only 70,000km on the clock. One owner from new with a full Honda service history and records! A brilliant find and a brilliant bike. And the best thing? She's a green one!!

[@walkingpictures]

Certainly a different rebuild for you Allen but absolutely love watching.Hope Charley Weaver approves!!Thankyou for posting the video,best wishes for 2023.Kimbo

[@somersetlevellersmtb5564]

Goodness me, I wouldn’t know where to start. Looking forward to the next episode 👍🏻

[@RideRestoration]

I absolutely love how meticulous you are with everything, A true sign of a great mechanic.

[@markwhite5465]

Thanks Allen, what a great christmas present..Happy Christmas to you.

[@josejmourente]

Es verlo trabajar ,con esa sencillez que lo hace increíblemente perfecto, los motores con usted están en buenas manos, felicidades

[@monkeybarmonkeyman]

I owned a 1993 ST1100 (Red). Finest bike I ever owned in 35 years of motorcycling. Used to solo tour on it in the states without a care. Absolute king of road bikes (imo). This is the engine I always hoped Honda would turn into a V6... redesigning with smaller bores to essentially take up the more/less the same space. It greatly pleases me to see you take this down. What a journey this will be!!

[@AllenMillyard]

I remember when they cam out in 89, I thought they were a V6 the fake extended cam covers made the engine look longer

[@liver.flush.maestro]

@@AllenMillyard Oh, no wonder where your ideas of adding cylinders came from 🙂... but ... are you going to make it a V6? 🤣

[@piearm1271]

Happy Christmas to you, many thanks for all the content.

[@stevebeaton2924]

I wish I had a quarter of your skills! Brilliant to watch. Thanks Allen.

[@ekoturnip]

Hi Allen, great video as usual. If you ever want to remove the engine from a VTR1000 and show people how to replace the automatic camchain adjusters and replace a cylinder head. This being one of the most common Honda faults. I've got one sat here you can demonstrate with :)

[@254lele]

you don't need to remove the engine to replace the cct on a firestorm

[@ekoturnip]

@@254lele mine needs the cylinder head doing and a bloody good clean up 😕

[@254lele]

@@ekoturnip remove the front cylinder dosen't need the engine off

[@ekoturnip]

@@254lele Maybe not usually, but bear in mind I was given this bike for free. It needs LOTS of cleaning/repainting.