Honda ST1100 Pan European repairs - Engine reassembly Episode 4

This is episode 4 of my Pan European repairs series. In this episode I am continuing with the rebuild of the V4 engine after arrival of a pair of brown spec shell bearings, seals and gaskets. This is not a step by step instructional video showing every single stage but more of an appreciation of what's involved in an engine rebuild and problems encountered. The crankcase sealant I used was Permatex Ultra Grey. hope you enjoy the video
regards
Allen Millyard

[@totalutternutter]

It feels strange watching Allen put an engine together with the same amount of cylinders as it had when he took it apart.

[@gntdriver2840]

when he had the engine stripped you can bet your life that he will have pondered if it can be turned into a V6 or V8 😀

[@monkeybarmonkeyman]

@@gntdriver2840 The only issue in turning it into a V6 (I WISH!) is the amount of work need to the entire bike. Not that he's not up to it, but the entire package would literally be a redo of Honda's excellent design. Not sure it would be much of a gain, really.

[@arthurpendragon9079]

He didn't even try to fit a supercharger!

[@penskib1975]

Maybe he feels the honda engine is perfect already. No improvements needed.

[@monkeybarmonkeyman]

@@penskib1975 It is an impressive package. I loved riding my '93... you could set out on multi-thousand mile journeys with absolutely no concerns. I did a number of them.

[@Κωνσταντίνος-ξ7θ]

What an unbelievable era. I can watch a video from a country far away. It made it a sir with a rare talent making engineering magics and i can comment in same time and interact. So many conveniences has to offer our era and i forget to remember that they are not granted. Thank you very much for these nice and educational videos sir.

[@Gruxxan]

thats a great tip for checking the torque wrench 👍👍

[@penskib1975]

Never heard anyone mention that.

[@mattyb7736]

Assuming your spring balance is accurate.

[@cme2cau]

@@mattyb7736 true, so you calibrate the scale with a calibrated weight.

[@howardosborne8647]

@@cme2cauIs the right response..... some just focus on finding useful solutions...others constantly search for another imaginary problem to throw a spanner in the works 🤣🤣

[@mattyb7736]

I have unfortunately found spring balances to be horrible in terms of accuracy over the years. I agree totally with the comment, weight suspended at a calculated distance is the best way to check. (Assuming your weight scale is accurate of course.)

[@davidortiz173]

Greetings Allen from Jensen Beach Florida. I was a Honda motorcycle mechanic for 20 years and this sure did bring back so many fond memories! It illustrates nicely how good Honda four stroke motorcycle engines are! Thanks 👍

[@hullygully1135]

I am a time served engineering fitter since 1966 and have been riding motorcycles since 1961 and I find it an absolute pleasure to watch Alan at work, I really appreciate your videos, keep up the good work.

[@johnb5519]

Great job as usual. Aren't these engines just marvels of engineering. I was almost worried you weren't going to have a cake break. It gives me an excuse to pause the video, and go down to the kitchen to grab something.

[@oscartravis5740]

I used to be so daunted by engines, but your videos have given me such clear, in-depth, no-nonsense information that I have bags of confidence now for getting stuck in. Always a pleasure to watch, both here and on Henry programmes on the box 😊

[@EdwinNew]

I am so impressed with the quality of the design of the ST1100 engine. Your quiet, logical approach makes the whole procedure crystal clear. I bought an ST1100 in 1998 and rode it for many years happily. I now have an ST1300, and I'm sure it's engineering won't be as good. The ST1100 was silky smooth and a torque monster. The 1300 is faster, but it never feels as quiet and completely effortless as the 1100 did.

[@ianseddon9347]

Another great and inspiring video, thanks Allen. That engine is a work of art, and the mechanic is certainly a maestro!

[@98Blackbess]

Excellent video, as always. Brings back memories of my 10 year ownership of an ST1100. Should never have sold it in hindsight.

[@timlane3650]

Allen your videos are a pleasure to watch,you edit them perfectly.I think you have earnt a knighthood for your contributions to the engineering world

[@mikebeatstsb7030]

The only channel in which video content IMO repeatedly deserves a click of the 👍🆙 'Like' button.

[@chrishartley1210]

I'm glad you mentioned that some torque settings are for dry threads, others are for oiled threads. I doubt if many people realise it makes a big difference, that oiling the threads when they should be dry will result in serious overtightening.

[@alextripp1230]

Hi Allen, another nice job, what a lovely engine these are. Looking forward to the refit into the bike next. Alex.

[@dozerblade]

I'd like to congratulate you Alan on your video filming technique, which is just something else you must have to think about and plan the shots and angles, along with the engine rebuild. Very easy to watch with your interesting commentary.

[@AllenMillyard]

Thank you it does take a bit of thought to film and edit each video 🙂

[@raygale4198]

@@AllenMillyard The framing and lighting are spot on Allen, your videos are always clear and easy to understand and full of top notch hints and information. That cup cake looked delicious 🙂

[@lasskinn474]

@@AllenMillyard we know that it makes much longer to work on anything to do the filming with thought, thanks, it's really nice content.

[@G58]

Thank you for sharing your torque wrench stories Allen. Your testing method confirms what I saw done in the calibration department during my apprenticeship. Your ‘hey now right mate’ Henry story is totally believable, and probably a good thing on reflection. Great rebuild.

[@Ekocart1]

Amazing build sir, people tend to panic while rebuild an engine and do mistakes which leads to catastrophic failures, but you have been quenched in time which makes you so damn good and have expertise 👍 Great work

[@klesmer]

I have never been a big fan of V4's Allen but this one is a real beauty. From the design, engineering and quality build it is pure Honda through and through. As a retired mechanic with 60yrs under my belt it pleases me to no end to see that our methods of doing things are almost identical. Hope to see more of your quality work. Stay warm Allen, I know what the weather is like in the UK this time of year.

[@bobhope3689]

God broke the mould when he made you Allan, your up there with the greats….

[@theshirehighlander7292]

Always a Joy to see your video. Mr Millyard.

[@antonoat]

Really enjoying this series of films, thank you for sharing this Allen!😊

[@davedelany2116]

Wouldn't it be great to apprentice under Allen's watchful eye. this is the absolute correct way an engine should be assembled 👌 Ive seen way to many people do some incredibly sloppy jobs cutting corners and leaving things that definitely need to be addressed a she'll be right attitude is never good during assembly, Alan is the master 👌 never a corner cut, if anything he goes above and beyond what is required 👌👌👌👌👍👍👍

[@PaulGappyNorris]

Never tired of watching these 😎

[@georgestewart1325]

Fantastic tip on how to check a torque wrench. Very much enjoy watching your channel.

[@ianperrin6782]

That's too much easy for Allen and for majority of us, but he's "really pleased for that" so it's ok. Allen, please bring us new videos of a new "Allen's bike" please please please :)

[@jimmyfleebot]

Ugh, I've just seen this upload and it's 8am and I'm at work. Now I have to wait 10hrs to watch it.

[@martinstone3656]

If the torque wrench was a jet wash from Henry it would be worn out 😅 The lightbulb moment is pure genius

[@jonunya3128]

you're an incredible mechanic, a pleasure to watch.

[@40spinup]

Finally someone else who uses silicone grease in the same as i do.

[@AllenMillyard]

It’s great stuff especially on rubber parts

[@handycrowd]

Love the torque wrench calibration tip, so easy!

[@LarryCarlin]

Every year, while doing the motorcycle maintenance, I make a video record of the work performed. It reminds me HOW DIFFICULT it is to make such good videos as yours. Not to mention the time to edit them! We watch every episode. Oh, and the Tea Delivery Service is just perfect.

[@AllenMillyard]

Usually around 12 hours in edit for a 18 min video

[@crabsodyinblue]

@@AllenMillyard my word that is a lot, thank you for all your work, it is so gratifying to watch.

[@4418CARLOU]

@@AllenMillyard Wow!

[@gteefxr3094]

That "is" a lot. Thanks, I enjoy your effort for sure.

[@Supernaut2000]

It's reassuring to do this detailed work knowing that the original engineering of the engine means it will last many years and several hundred thousand miles of enjoyable riding.

[@deancoley7987]

When Henry bought the torque wrench, he may have thought it was a talk wrench and used it as a microphone lol (:forgive me Mr Cole) . The advice and learning will benefit anyone who assembles and disassembles any machinery, learns so much via the videos, and enjoy every minute. Cheers Allen

[@corndog6700]

Allen, you mentioned torque wrenches. I used to work for a drag race team, that was sponsored at various times, by Snap-On, Mac, Matco, Cornwell Tools and (I believe), Proto. Might be mistaken on that last one. There was one toolbox in the shop that had maybe 75 torque wrenches in it. When I first started there, I went to use a torque wrench and one of the guys said to check any one I used with the tester on the wall. Out of every one I checked, only 2 in that whole tool box were in spec. So I'd have to set the tester to my specified torque, then adjust the torque wrench, if I needed 65 lb ft, keep adjusting until it clicked at 65 lb ft, even if it said 35, or 90. Even if someone paid $550 for something that said Snap-On on it, didn't make it read any more correctly than anything else.

[@frenchenstein]

🌟I love these engine strip/repair/rebuild videos❤️

[@johnfrench9608]

Great wrenching Alan. I always click a torque wrench twice no real reason just do.

[@Area51dog]

Well done again Allen. Another clear and concise video.

[@thekeitohappiness]

I'm certain those connecting rod bearings were NOT cheap. Went through the same thing on my vintage goldwing. The NOS replacement bearings were double the cost of an entire engine with a quarter the mileage. Too bad there isnt a manufacturer who would reproduce these - bulletproof engines these are.

[@fredziffle1991]

The guys an absolute master and a pleasure to watch.

[@DurokSubaka]

Fantastic as always. It’s good to see Charlie’s on the job.

[@dcxplant]

I'm so happy for you! Finding rare parts for a motorcycle you love is always a thrill. THANK YOU so much for the torque wrench test. It never occurred to me to use a scale. Simple yet brilliant. PS: You okay? Seemed a bit melancholy on this vid. Be well ✌

[@RE650NZGraeme]

So fascinating! So many different camera views and setups for each action stage - so impressed with the attention to detail so that viewers miss nothing of this meticulous rebuild for our benefit!! A mission of perfection! Thanks Allen!! Two days work done in 20 minutes viewing pleasure!!

[@inkydoug]

I have even more appreciation for my ST1100 after seeing how excellently made the motor is on the inside. A rare sight to see, as they regularly go for 100,000 miles without a hiccup.

[@KristopherNoronha]

100k might be an unterstatement, they usually get scrapped for other reasons with the engine never being opened 😁

[@The_Touring_Jedi]

​​@@KristopherNoronhaorrect.i If oil service done by the book this engine usually stays alive longer than the other parts do. Rust is the only issue on this bike on the back swingarm depends in which climate is the bike moved. I had 27 years old ST1100 and it runned perfectly with all original parts. Now I found ST1100 1991 with low mileage and plan to buy it really cheap and keep it longer as I plan a trip trough whole Europe with the bike without touching anything on it besides normal servicing.

[@kinnaird100]

Could watch you all day, I wish I had fraction of your engineering skills.

[@ukurtlele1494]

I didn't know the UK had "assemblymen" until I watched this. I guess the proper address for that is "Your Honor", which is appropriate for Allen.

[@Biffatheriffa]

Honestly these videos are therapeutic!!! Though I am now on tenterhooks to find out if the crankcase tick and gearbox whine are sorted!!!! Thanks for the torque wrench accuracy check tip Allen!!! Can't wait for next episode.........😀👍 oh, and Tracey is still such a babe !!😍🥰❤️

[@rdaystrom4540]

I just love watching your videos. They always make me smile. Wow. That engine is complex and amazing. Hey, I have something in common with Allen. I drop bolts in engines. Haha 😄

[@tinks43]

Rather you than me Allen. Great job & thank goodness for the extendable magnet 🙌🏻

[@Farlig69]

Yay another vid to slake my AM addiction!!

[@chrispy104k]

"That was close", hahaha, I'm sure you did that deliberately to demonstrate how handy an extendable magnet is. Good job.

[@howardosborne8647]

Just what I'd expect to see from Honda...a tremendously well designed engine. The spring loaded anti backlash gears are similar to what was fitted to the camshaft drive on the RC30 motors. Still very puzzling how that one conrod had an incorrect set of shells fitted though.

[@derekcomer4858]

The engine looks so well thought out and beautifully engineered, this one will run so well after such a careful rebuild. Was desperately hoping a cupcake would make an appearance, and I wasn’t disappointed ☺️

[@jbadenho]

i wish he would stop working and just put out these great videos. i can watch him work all day. Legend.

[@alisonmoxon7519]

Fabulous watching you Allen.. yr skill and precision is amazing. Top Man👍

[@JustSomeVideos0]

Lovely! It looks easier torqueing that clutch nut up out the of the vehicle than when I last did it- on my back under my kit car trying to torque it to 110Nm (IIRC). For about a week afterwards I couldn't walk properly. Oh the joys :D PS jealous yours is a 40A model. My one is the earlier 28A, I've got a later 40A engine to swap (in a car 28A is a bit light) but as you mention they're heavy engines so to date I've just run the 28A and used LED lights!!!

[@Jesse-B]

You make it all seem so easy Allen, just perfect!

[@allanmaureenmacintyre4474]

Brilliant tip for checking the Torque Wrench. Thanks.

[@Gruxxan]

when i used to rebuild engines, i'd smear thin film of LM grease on both sides of any paper gaskets. they would never leak, plus, if you ever needed to strip the engine in the future, the gaskets would just peel off in one piece, rather than have to scrape them off, which is tedious and time consuming

[@pl1068]

What a joy to watch, that ST1100 is going to last another 20years 😊

[@GadgetMart]

Allen, I’m in awe and I’m sure the Honda mechanics are getting a lesson on how it’s done too (all about speed sadly on a production line). The engineering of that bike looks perfect, we are only going backwards in engineering quality.

[@gs1100ed]

We should be asking WHY is this happening? WHO benefits from using this approach? It’s clearly NOT what WE want!

[@GadgetMart]

@@gs1100ed bit deep that Jeff. We are watching a great bloke fix engines in his shed.

[@gs1100ed]

@@GadgetMart thank you for pointing that out. You’re right! It’s never good to take life seriously. Just enjoy the ride.

[@GadgetMart]

@@gs1100ed Nothing we can do about it. My bikes are both old for this reason. Indeed enjoy the ride 👍

[@gs1100ed]

@@GadgetMart I guess my problem, is that I have never been the sort of person who shrugs my shoulders and says “oh well! Nothing I can do about it. Let’s just have another beer and watch some more TV” I believe mankind is smart and powerful and can achieve great things if they put their mind and energy towards a desired goal. I have not given up and resigned myself to just accepting things as they are. If that is your predilection, then I just feel sad hearing it. Entirely too many apathetically folks in the world may actually be the real problem.

[@dean-does-stuff-81]

I for one cant wait to see this thing beat again. (and now with the 2 original build faults remedied, I suspect it will be running just perfect)

[@Devo491]

Absolutely mesmerising! The dispassionate monologue is soporific, and the action so engrossing, I could watch all day long. Thank you Sir, you're a National Treasure!

[@dartmoormancave]

Thanks Allen, great vid......looking superb, it'll be back on the road soon!

[@Dazg-666]

Brilliant video Allen you make everything look and sound so easy the way you explain everything.keep the good work up your a national treasure 👍👍🤘🤘

[@paulthompson8613]

I think yourself and your good lady might be receiving a card and maybe some cake this Christmas from the Honda ST1100 owners club this year .🌲

[@NateG3678]

You’re wife Tracey is an absolute saint!

[@ridethroughlifertl]

This man is a mechanical wizard. Knowing where to go for all the important information to rebuild an engine properly is 95% of the battle. I can't get enough of it.

[@mrsmith4662]

You know what, I bet Alan is only one of a few guys in the entire world that has ever done this imaculate restoration on this engine. The vast majority of owners, just continue to ride it worn, then sell it or scrap it. This level of perfection on such a complex unit is unique and kind of convinces me I should be able to complete the comparitively simple rebuild of the bits of Norton in the garage, which is just like Mechano in comparison. Love the series (and so well filmed).

[@jonathanbitsch5780]

Please don't underestimate old bikes and their parts! Some things get more and more complicated - I've had hard times with several old 500 four carburetor assemblies. Especially with the engines, you'll have to be extremely attentive for worn parts in places you don't expect them, being used to newer stuff. I have often found myself unsatisfied with my results. I learned that you have to take your time and try to do these pieces of history justice! Greetings from Germany.

[@anthonycarty9433]

If you're comparing your Norton to mecchano then my Maico engine ( which I've been "rebuilding " for the last twenty years )must be Lego bricks .

[@mrsmith4662]

@@anthonycarty9433 You're a restorer after my own heart. The Norton (Dominator 99) has been in bits since the mid 1980's. I'll get around to it 'soon'.

[@gregkieser1157]

What a lovely series Alan - loving this series and the wonderful engineering that went into these beautiful engines.

[@Colin_Ames]

Excellent video, as always. Thanks for the tip on checking the torque wrench. I recently bought a cheap one for a particular task, and it seems to take more effort than I expected to reach the specified torque. Of course, it could just be that my 70+ year old arms are weak!

[@alanobrien1817]

Fantastic video explaining everything as you go along, proper job 👍

[@Mannix2023]

Looking forward to see you mastering the motor

[@SomeGuyInSandy]

Ready for many more years of service!

[@thedave7760]

Thank you Allen you are an inspiration. You made me realise that one day I might be able to disassemble and put an engine back together. One day I will it is now a goal and it is thanks to you.

[@tonymarkey6525]

Great to watch and looks so effortless. Of course that is due to the diligent preparation and checking that I know must go on. It’s just such a treat to watch and as usual thank you for sharing Mr Millyard!!😁😁👍👍

[@stevie5141]

Another great video… great stuff as always.. good to see you back Allen

[@MrSheymie]

Very therapeutic to watch the assembly. What a beautifully made engine.

[@nailseaphil3989]

Thanks Alan really enjoyed the rebuild work. The videos are looking very professional.

[@JT-si6bl]

Really nice attention to camera angles, too. Lovely work!

[@BikerBroughy]

Great video as always Allen, did notice something that surprised me though, all them lovely genuine Honda seals, gaskets and o-rings you used, but then a non genuine oil filter. I've always wondered about the quality of hiflo oil filters as they are everywhere on the internet, but always stuck with genuines, but if they have your seal of approval then they must be decent enough, so that will do me nicely... And as always love to tracey.

[@AllenMillyard]

They look to be good quality and well made I cut open the old filter to look for particulates

[@Elvis20101]

Thank you, I did enjoy watching.

[@chriscanning8591]

Absolutely loving the St1100 videos alan 👏

[@1957kwick]

Tech tip) always wind your torque wrench back down to zero after use. to relieve the tension on the spring.🇺🇸🛠🇺🇸

[@MrDurham55]

Well who would of thought...?

[@gntdriver2840]

thats true,also you should never use them to undo any type of fastners.

[@howardosborne8647]

A spring being left in a compressed state within its working design range isn't where the problem really exists. It is the repeated cycling of loading/unloading a spring which causes a slight loss of elasticity over a prolonged period of use.

[@noelcastle3986]

I've been dreaming about brown bearing shells since your last episode great to see they arrived and fitted perfectly no need for plastigaguage checks. Great tip on checking torque wrench calibration will be checking mine asap. Using a dial indicator to check big end clearances another great tip. Looking forward to seeing the engine refitted and running smoothly and quietly as only you can do perfectly.

[@wattie1050]

Faultless work as per usual , got to love those Honda engines great design .and good to see Charlie weaver still keeping an eye on things .😁👍

[@Jimmyboypepsimax]

Another Great video, brilliant to see another lover of Bahco tools!

[@gerryjamesedwards1227]

This is the first time I've managed to catch one of your videos during a break from working on my bike, it feels great to enjoy this without the guilty thought of "I should be working on mine".

[@Chr.U.Cas1622]

Dear Mr. Allen Millyard. 👍👌👏 Extremely well done again and as always (video and work). Now I'm eagerly looking forward to watch/hear this engine run again and in what you will turn your older ST 1100. V6, V8 or even more? 😁 ;-) Thanks a lot for making teaching explaining recording editing uploading and sharing your meditative/meditational videos. Best regards, luck and especially health to all of you (including the hedgehogs of course).

[@NOELTM]

Remarkable engineering from Honda, amazing skill and knowledge from Allen and as enjoyable to watch as one of those cupcakes for sure! Thank you!

[@dord1954]

coming on nicely Allen and I can see that the time you spend with Henry has taught you a lot about engine reconditioning, you must be forever greatful to him :)

[@howardosborne8647]

Henry Talks a lot whilst Allen torques a lot🔧

[@AllenMillyard]

I have lernt as lot about masking tv programs and editing 🙂

[@philboyes2669]

Great stuff, thanks saying what the sundry products are too

[@richardday3862]

The st1100 engine seems more like a car engine in its cam assembly and alternator set up. Stunning work as always Allen!

[@Morannar]

Not to mention the separate gearbox! Gorgeous engine

[@clivehale397]

Hi Allen a wonderful rebuild film how on earth do you remember the order to put it all back together....you are a real gem to watch. Can't wait for the next one as I know you had some problems with this engine ,that's why you took it to pieces Anyway look forward to the next episode.

[@hugieflhr03]

That looks like a really good engine to bolt into a go cart. It does have some tricky parts but you do an excellent job as usual to point out how to handle those areas

[@cv5645]

National treasure. Loved this rebuild.

[@robwebber1217]

It’s like one of those mechanical watch assembly videos where you always wonder how they know where all the bits go. 🙂

[@LTVoyager]

The secret is a good service manual.

[@techo61]

Started with a good aptitude really, if you don't have the aptitude to begin, no amount of reading will help.

[@ray1961RAY]

Excellent video as normal Allen and also nice to see Henry's torque wrench seeing the light of day and getting used 🤣 Keep up the good work 😉...

[@jonford6119]

Love the way you don't want t get oil on the cambelt, but don't mind getting it on the cup cake.

[@marksimpson5218]

The cup cake looked a bit dry, the oil will make it go down easier.

[@jeffshootsstuff]

I can't believe I never learned how to actually check a torque wrench. That's very useful. Plus, another fascinating video, thanks!

[@anthonycarty9433]

I was amazed at how simple it was . I had bought a new ish one and was going to send it off for a calibration test , not now . Just have to make sure of the accuracy of the weighing scale .

[@pigpenpete]

@@anthonycarty9433 You'd have to get your scales calibrated for the results to be worthwhile

[@JohnSmith-yv6eq]

@@pigpenpete Unless you have those old fashioned grocer's weights that they used on old balance beam scales?

[@howardosborne8647]

@@pigpenpete That is why calibrated weights exist.....always a solution if you want it bad enough.

[@doluggs]

Hi, Allen Your videos are always a pleasure to watch. I am tempted to do the same job on my ST1100 - but I am sure that you do it much more accurate - just perfect. 😉 Thank you.