Kawasaki S1 550 four cylinder first start, ignition timing and carbs. Episode 7

In this video im finishing off my 1974 Kawasaki S1 550cc four cylinder engine build making the stator plate to fit 4 sets of contact breaker points and setting the ignition timing. Stripping, cleaning, repairing and fitting the carbs then fitting a set of Delkevic H2C chrome header pipes. I then take it to my friend Henry Cole's farm in the Cotswolds where there is no issues with making a bit of noise. It was a bit loud at times, but the engine started pretty easily and runs really well considering its on open carbs and headers. I will be fitting it into bike in the near future and will post a few videos as it progresses.
Thank you for watching, I hope you enjoy it.
In the video I used clock cleaning solution for the brass bits and alloy wheel cleaning solution for the aluminium parts which is easily available at online auction sites.
The alloy wheel cleaners vary in strength so check first with a spare part to ensure the finish is what you expect, the final finish depends on the make up of the alloy parts. My solutions are 5yrs + old so are quite dilute by now.
I like to make my engines and bikes at home in my garage and shed using the tools and equipment I have to hand and working with hand tools rather than sending parts out to be made or machined.

[@Banditmanuk]

"It's so peaceful in the Cotswolds" 🤣 That engine sounded perfect. We are in awe of your talent Allen.

[@enyaisrave2831]

👌👍

[@robinbrowne5419]

It's so peaceful in the Cotswolds... Birds chirping, crickets singing... until Allen shows up, that is. Lol.

[@viniciorota2407]

:v:vv:ģ^&^

[@lgulb7299]

0000000000

[@captainaverage721]

@@stujones3566 A 24 cylinder merlin engined Spitfire!

[@randomtraveler3363]

the grin on your face when you fired it up was priceless. fantastic project

[@helgaschmiedtmarcelofalcao2246]

I was also very pleased with that!

[@markwybierala4936]

This brings back some wonderful memories from high school. In 1976, I was very fortunate to have a dedicated motorcycle repair class with a well equipped work shop. It was run by a great teacher and mentor Jim Capps who taught me to never be afraid of a mechanical challenge. He pursued engine mods just as you do boring and resleeving, adding domes to pistons and such. We had a small boring machine and I rebored my S2 along with disassembling the crank to replace the inner crank seals. Getting the crank straight again was quite a challenge and very few people understand what is involved with pressing a 3-cylinder crank back together. But we did it. I found a book describing the equations used to design expansion chambers and be fabricated a set for my 1972 S2. What a wonderful rocket. Real properly tuned expansion chambers make the greatest noise - so crisp and bright. It was a great adventure and taught me that anything was possible. I owe a lot in my life to Jim Capps.

[@jackheinemann1994]

That was nice to read, thanks for sharing

[@joseywales3789]

Charlie Weaver, Barbecue, Swiss Army Knife but I miss Greta on the Ericsson Phone, the hedgehogs and I really Miss Lady Traceys Wonderful Cup Cakes..... but really, Sir Allen Millyard, you are an Engineering Genius and Watching the build, from start to finish, gets my creative juices going. Perhaps I'll fix that picture frame that's annoyed me for the last two years, or perhaps I'll sit here and watch another Allen Millyard video on KZbin! You are a British Treasure! Thank you for bringing us along.

[@AllenMillyard]

don't fear the usuals will return in the next video

[@Shining_Whit]

With all the meds I am on at the moment, this is really all I needed to cheer me up! I could almost smell the two stroke through the speakers! Allen, your vids always make me smile and give me a lift when I need it. Thank you so much.

[@CONEHEADDK]

Hope you can, and will, get better.

[@peters9929]

hope you get better soon

[@mausermann7918]

Never seizes to amaze me what you're capable off wit a rather limited range off machinery. "So I took my hacksaw...." and made a perfectly running engine in my shed. Unbelievable, you really are an extremely talented machanic, a true British understatement.

[@chrischappell9824]

That smile at the end let’s you know that another masterpiece from the garage lives and Greta is hiding under the duvet. Amazing work Allan, amazing work.

[@andreassvensson1038]

Honestly. I don't think Greta givs a rats ass about guys who start up old engines.

[@LongPeter]

"And then it caught fire." Is my favourite thing ever to be said in Alan's deliberate, enthusiastic tone.

[@LiquidAudio]

Ha ha, so true, I laughed when he said that! 🤣

[@simonsackett]

Great! I've been looking forward to this!

[@doctordapp]

Let it scream! I love 2-strokes and really love how easy you explain everything everytime!

[@TheMissendenFlyer]

Brilliant Allen, I could almost smell that!! Great stuff as ever....

[@AllenMillyard]

It’s a bigger version of the one you rode

[@TheMissendenFlyer]

@@AllenMillyard Cool!!! Roll on Spring, it's about time I took you up on the offer of that Viper pillion ride!!

[@CLCIII]

Allen is a certified mechanical GENIUS! That motor sounds mad when revving and awesome at idle! Brilliant as Always!

[@Albatrossamongus]

Thanks for all the effort you put into your channel and these videos Allen, seeing a master at work like this is fantastic!

[@MartsGarage]

Wow Allen, that sounds absolutely great. It's a credit to your ingenuity. I'm a car guy but really enjoyed this series. I was very impressed with the results of the two cleaning solutions, especially on the very bad one. I liked the two workholding methods you showed on the lathe too. I'm a car guy but really enjoyed this series. Mart in Solihull.

[@dougg1075]

A master. He’s got a eighth degree black belt in motorcycle building. AND his wife is a good cook

[@banmadabon]

In Italy we say that guys like you have "mani d'oro" (Golden hands). Every time I watch you working it's pure amazement. Keep up the good work!

[@lesmaybury793]

Marvelous. Alan and Henry could sell tickets to an engine start event like that. Really looking forward to seeing that engine in bike and blasting through the countryside.

[@cannonEDHA]

I’ve probably said it before but ill say it again history will remember you Alan and the amazing work you have done over the years not just for your own pleasure but for everyone else’s too . Keep the projects going top man

[@lawrencekeating5571]

Allen’s huge grin when it first started outside says it all. Like a kid and his first bicycle 😁. Awesome job Allen. 👍👍

[@sugizotakuro]

boys will always be boys. look at allen's face when the engine revs smoothly. MY TOY WORKED PERFECTLY!

[@lukaszkramarski278]

Mistrz. Autorytet dla mojej skromnej osoby. Dzięki niemu kupiłem TIG'a z zamiarem przebudowywania silników. Pozdrowienia z Polski!

[@johannviljoen64]

That thing sounds angry, just as planned. Can't wait to see how it performs. Your friends are very impressed with your success with this motor!

[@kevinchamberlain7928]

Alan, myself and another old biker (one of the founding fathers of the Outlaws mc North Wales) discussed you at length and agreed you are a genius. We already knew, of course but that's what we did.

[@RIZMINE]

Smile on everyone’s face when the engine started that including me as well Sweet 2-stroke 👌

[@Spodokamono]

What is great to see is all the joy and smiles on the faces of grown men starting up a newly built two stroke engine. I was smiling with you Allen with the engine on the back of the truck as the engine was revving away. I am sure the same applies to all who watch this video. Just fantastic Allen thanks

[@Nifilheimur]

Amazing as always Allen. Motorcycles are just such wonderful things. Best anti depressants ever invented and two strokes always bring back fond memories!

[@rodcurrieclassics8102]

I could smell the castor R......Hmmm..mmm!. Lovely work Allen. We all think we're handy engineers until we see what you do. You, Sir are a national treasure.

[@crudboy12]

I have got to adopt your thorough carb cleaning methods; they came out great for how badly corroded they were.

[@Robert-ns7id]

I am blown away by your skills much respect from Canada .

[@CONEHEADDK]

The good people of the world are blown away by the strong Canadians in Ottawa these days !!!

[@Elgarman]

@@CONEHEADDK Stick to the point. 🤦‍♂️

[@CONEHEADDK]

@@Elgarman Do as you please - so will I.

[@Elgarman]

@@CONEHEADDK But you're not. Over and out.

[@CONEHEADDK]

@@Elgarman I don't even understand your last comment - a shame you are "out" and can't explain. I'll be out too then, from conversing with you.

[@grenvillephillips6998]

I was amazed at how well that carb, which was trying to be a snowglobe, cleaned up.

[@MrMartinious]

You my man am an extraordinary genius! Sadly you are a dying breed!( hopefully not) I've had many hours of watching you calmly reinventing the wheel! Bless you 😊

[@DouglasNicholas-el5hv]

Thank you for your time and effort.! I certainly will apply your teaching. You are very skilled and helpful for other men.. Much appreciated 🙏 Have a blessed life. Again. This was so informative and a real assist.

[@andyplage6590]

As always another amazing video from the Master of Engine fabrication its just unreal how a man in his garden can achieve such precision Engineering well Done Alan 👏

[@1eltino]

Incredible. I love those kawasaki engines and to be able to see and hear a 4 cylinder version is music to my ears! Very well done Allen, if I ever win the lottery I shall give you a blank check and ask you to build me one!

[@cnniraq4517]

You are a good and creative man and your wife is a beautiful and kind cook. Greetings to you and your wife❤❤👸🏼❤❤

[@AllenMillyard]

Thankyou

[@thewatcher5271]

I Watched Most Of Your Videos So Many Times & Every Time It Makes Me Want To Go Work On My Bike & Keep On Living. Thank You.

[@hjujitsu6523]

Not even started and can sense the pure genius

[@andyhill6398]

Looking forward to this.

[@preonmodel8354]

Having my Dad and Uncle as Rolls Royce trained mechanical maintenance engineers this is up my street.. very clever solutions that come so easily.. I have to say, that in your videos you make it look simple and to you it probably is 😎 Amazing work and fun to watch thanks Alan 💪

[@blankeny]

A few years back I did this when I did a complete restoration on a Honda 550K. The bike came out gorgeous and I sold it for a bit over $3500. Considering I payed just $60.00 for the bike and took six months to restore, I think I got a good deal...

[@abdulrahmanaljamea8458]

I am a 40 year long auto mechanic i like to tell you are doing extremely professional clean work,, thanks for sharing,, simple note ; ignition timing will be fixed no acceleration advancing ,, greetings from Iraq.

[@stwilfridsneedle795]

It always amazes me just how crisp your fuelling sounds..especially on first start up. Nice one Allen.

[@leslieaustin151]

As good as ever! You never let us down Allen. I especially liked the machining tips. Might try some of those techniques myself. When this video came through I was just rewatching your rebuild of your son’s Honda 175/250 engine. That is one of my favourites. Les in UK

[@matus1976]

It's like Bob Ross meets Einstein of engines, such a pleasant and amazing channel, thank you for making these videos, you are an inspiration to builders everywhere!

[@RustyRecovery]

I've been watching and enjoying all the engine builds on your channel. The Kawasaki engine sounded amazing. What a fantastic job you made of it! Then to top it off, Henry Cole shows up who's motorcycle rides and shows have kept me entertained for years. Thanks for sharing. Jason

[@MM_in_Havasu]

Your efforts have, once again, paid off handsomely, Allen! Will be looking forward to hearing that sweet engine sending exhaust through 4 expansion chambers! Your extensive fabrication skills also receive proper accolades from me with the little bits and pieces you manufactured to complete this project. Thank you once again for a wonderfully interesting video, cheers!

[@182Warren]

You make it all seem so easy , you are like a surgeon with that hacksaw , fantastic content

[@earl6969]

That engine is fantastic...but the grand prize is that all-knowing grin of personal affirmation. Proper

[@eighthof8]

Wish Allen lived approx 4527 miles closer. Just bought a '74 H1, and would very much like him to rebuild the engine and trans, but alas... You're a magician Allen!

[@691053]

Wow! Incredible work and engineering again Allen! You make this look easy and no stress, one step at a time and it comes out… perfect. Your sense of humour and your editing talent make your videos real masterpieces. Thanks!

[@AllenMillyard]

Thankyou

[@dukiemoto8676]

Thank you for bringing this beautiful two-stroke creation into our world. It helps soothe the anxiety over the ever looming electric tidal wave. Please don’t stop you’re amazing. The one and only Allen Millyard, absolutely incredible! Thank you

[@PhilipBallGarry]

The Electric future certainly is a tidal wave of depression 😔. I can imagine how the Borg felt 😢

[@boatlover2296]

This guy could build anything with a hacksaw and a screwdriver. Truly amazing guy.

[@billide1463]

Here in Toronto it's minus 17 celsius and and there is a foot of snow everywhere. Watching several of your videos has inspired me to start rebuilding my 1971 Honda Z50 minibike which has been calling out to me from a corner of my cellar each time I walk past it. Perfect time to get started on this to be ready for Spring. Thanks for the push. Love your fabrications.

[@NathanNostaw]

I can only imagine the excitement when that ran and then reved. Thats sure going to sound good with a full exhaust system. Nice work!

[@jamesgates6121]

Never cease to amaze and inspire! Love watching your builds Allen 🙂

[@teneretraveller8980]

Brunel, Stephenson, Millyard. Great British engineers. Simply superb. Thanks for sharing 👍

[@prostwest]

Turned it way up on the real stereo and WOW. Next best thing to being there. One request: for some reason I really enjoy seeing the gasket-making with the swiss army knife! It's practically therapeutic; please don't skip that!

[@elmerfudd1086]

Oh ...what an incredible sound!!! I absolutely love the sound of a 2 stroke multi just above idle. Reminds of a top fuel dragster at idle. Thx Allen, that was "just perfect" .😜🇨🇦🇨🇦

[@georgobergfell]

These first engine stsrtups really never get old. Nice job as always, Allen!

[@normanfawley7379]

To see is to believe ! It's all been said,Mr.Millyard is one very fine chap ! His knowledge and skill is to be marvelled at ! Great stuff.

[@Herzankerkreuz67]

What can I say....... The undisputed authority, the genius himself, Dr. Magic at work showing his skills to the world. This is sorcery and witchcraft 👍🏍💪🙏

[@paul2457]

Amazing sound! Great work! Can’t wait to see this in the bike. Love to watch these episodes, thanks Allen!

[@Speedytrip]

Amazing work once again, I can only imagine how satisfying it must be to see things work out just as it was planned in your head!

[@PoppinWheeliez]

A tremendous amount of knowledge gifted in a 20min video.

[@BaffledApe]

So I've been waiting to have time to watch this series and basically just binge watched the whole build! I did a 5 year engineering apprenticeship 1976-1981, used that very lathe, mill and all the hand tools, micrometers and dti's etc. First bike FS1E, (borrowed a C70 to take my test on 17th birthday) then GS400, CX500 (Year off in/out of hospital/learning to walk after coming to major grief on beloved CX), Back on a new CX500EC, then GPZ1100, GL1100, FJ1100, Triumph Trident, Thunderbird, Sprint Sport -- I am flabbergasted at Allen's skill and experience! The way he uses the lathe to set up the crankshaft, points stator plate etc, is 'out of the box' thinking genius. And Allen your camera positioning, lighting and editing has risen to new levels. Love the cooking segments and the wildlife. My favourite KZbin channel by far 👍

[@MrTlmckee]

Absoloutely perfect! I look forward to every video. Keep them coming. Thank you for sharing your projects.

[@theflyingfool]

Marvellous! There's nothing like the whiff of two stroke :D Brilliant job you're doing Mr. Millyard!

[@MotoTvWoodsFarm]

nice movie enjoyed watching, after rebuilding a truck engine that hasn't run for 3 years that was home for a family mice, I find very helpful watching you work through issues. wonderful pleasant calm nature.

[@adolfheitzer3183]

Meinen höchsten Respekt vor diesem Spezialisten! 👋👋👋👋👋

[@mattrooke3210]

Wow 🤩, loved it when that engine was started at Henry’s farm sounded awesome 😎. Always in awe of your engineering skill.👍👍

[@ArcturanMegadonkey]

That sounded beautiful! great to see such amazing crafts and workmanship to make parts for what ever is needed. brilliant video Allen. Paul

[@joebufford2972]

I'm seeing this more than once and I enjoy it each time. Thank you, Alan

[@markmiwurdz202]

Allen Millyard - M.B.E. That's "Master Builder of Engines". Great work Mr. Millyard sir! You and yours stay safe and well.

[@brucemitch928]

That engine sounds awesome, expect no less from the mechanical master himself. It’s going to be a hooligan of a build, looking forward to seeing and hearing it in the frame and on the road. 👍👍🏁

[@Jaysqualityparts]

Awesome Allen.

[@j.w.3345]

Hi from Massachusetts. I always enjoy watching you work. Amazing skills. It takes me back to my 71 H1 500 that I rebuilt when I was 18. So many great rides! Thanks for bringing us along on your builds.

[@mauriceholder1386]

You're braver than I cranking that by hand. I had an elsonor 250 two stroke that would flip me over the bars when it kicked back. Amazing creation though !

[@Prestonesfpv]

The man with endless cool projects, very impressive workmanship 😊😊 fun fact, i would love to have a truck like yours, but here in Denmark it would cost aprox 2000 GBP in annual roadtax to own

[@laurieharper1526]

It's getting that way in the UK these days. They charge us road tax based on engine size/CO2 emissions. They're trying hard to coerce us into driving EVs.

[@larsfrandsen2501]

Invaluable videos for the rest of us, Allen! I feel like I am an apprentice mechanic, studying the craft with a natural genius (where were you and KZbin when I was wrenching and tuning motorcycles at the age of 15-20.) I am a returner and need all the advice I can get. Your videos are golden! Although I hasten to add that I will leave my GT750 with three cylinders. Three is more than enough for me. Thanks again!

[@andrewknightley6799]

Another absolute classic episode more classic Millyard cheered me up.

[@CentaurUK90]

Utterly fascinated and in awe of Allen's talent. Who'd have thought it was possible to turn 2 x 3 cylinger crankcases into a 4 cylinder with just a hacksaw, some milling and a TIG. Absolutely brilliant stuff !

[@johnjones4825]

13:01 I was also taught to put nothing but liquid or air into a jet. My reasoning on that is that copper is softer than brass (thus shouldn't harm the jet), so I strip a piece of copper cored electrical wire, using one or two, maybe more strands to poke around in the jet. The number of strands depends on the size of the jet, more than one strand almost seems to be like a wire brush.

[@vicamaral]

hope he greased the points arms were it rubs the crankshaft?.

[@Ozsmallbore]

@@vicamaral 🙄

[@andrewwallace8700]

Hi Allen, great video as always. I love to see the engineering that goes into these engines, it's quite incredible to be honest. However, I have one question... I get having the four sets of points makes some sense, but given that once adjusted for gap and them all being mounted onto the same plate, how do you adjust the timing for each one individually? Keep up the good work, cheers Andy😀

[@jasonsmith6074]

yes i wondered that as well,once set its set

[@oceanhome2023]

There would be no individual adjustment each TDC is exactly 90 degree the only adjustment is for the entire disk plate to be rotated

[@andrewwallace8700]

@@oceanhome2023 Agreed, just that Allen implied (I thought) in the video that he wad adjusting each one individually... thought I was going mad to be honest! Cheers, Andy

[@doccops]

You slightly adjust the points for each cylinder...

[@oikkuoek]

Second hand crank after fully handmade ignition system.. And then the carbs, with almost idle, it probably would've idled if there was some fuel pressure from a tank.. What a build, Takumi-San, what a build.

[@williammitchell1785]

Perfection as usual this man could probably build a rocket to Mars out of some old parts lying around GENIUS! can't wait to see it on a frame and ridden 👍🏍️

[@bikesmith]

Very very cool! The bitter sweet moment was all the smoke and unburnt oil pollution. Sorry.

[@Matthew-wn8oq]

I watch him in awe! He is not human , I really believe he is a super being.

[@firsteerr]

yet another twenty minutes over far too quickly !! brilliant work man and shed in perfect harmony

[@tfjack97]

For got to mention how great those carbs cleaned up, like new out of the box. Excellent way of cleaning the brass parts, and never would have thought to use the acid to clean the carb bodies.

[@bobmurphy9380]

Fantastic Allen, great skill. There ain't many like you anymore.

[@Thouveninpascal]

That incredible build quality of japanese industry.. 50 years later. And amazing perfectionismof "Sir" Allen Millyard.

[@stevengarforth4244]

Great video Allen. The smile on your face when it started said it all, and your dribbling nose too. Excellent once again 👍🏻👍🏻👍🏻

[@martinhughes9769]

There's engineers and theres fitters your one brilliant technical engineer 👏

[@bradleysmythe1719]

Amazingly crisp, especially off idle. cannot hide that grin hey when a hand built bespoke engine turns out that great. I'm definatly looking forward to the next video

[@jereerej]

So many things to learn through your videos... And such a peacefull time watching them. Thanks from France :) :)

[@johnny.kreator]

Mr. Allen, I don't know how to put this in more appropriate words due to the language barrier... But you are a MONSTER in the area of ​​mechanics.... Greetings from Brazil !

[@alamocannon3791]

Missed the cookery lesson........... Allen, You make it look so easy... can`t wait to hear it tearing up the A4.

[@kingearl2596]

Mr. Alan says often "just perfect" - and it is really! Thank you for the nice Video.

[@kbjerke]

I am not worthy to comment on your workmanship and inventiveness. But I will anyway. *SIMPLY BRILLIANT!!!* Thank you for sharing your experience!

[@AllenMillyard]

Thank you

[@debianowns4393]

Sounds amazing, runs amazing and doesn't even move! you are one hell of an engineer! Incredible work Alan.

[@billmoss7320]

Another example of the genius that is Allen Millyard,I can't wait to see the finished article.