Honda ST1100 Pan European - the engine rebuild commences - Episode 2

Episode 2
In this episode I continue to strip the engine from my red ST1100Y removing the crankshaft for checking over and measurement. then start the re assembly of the engine and rebuild the gearbox. see episode 1 for details of why I decided to strip the engine and what problems I was experiancing. This series are not intended to be step by step instructional videos covering every detail but more of a flavour of what goes into a full strip and rebuild with the usual interludes in the kitchen and garden.
Thanks for watching
regards
Allen Millyard

[@AllenMillyard]

Ive noticed a few comments questioning the use of assembly oil on the big end cap nut threads before they are tightened with a torque wrench. This is a specific requirement as detailed on the official Honda spec sheet for the ST1100 engine to lubricate the threads.

[@ChrisSofos]

Totally agree! The assembly oil is perfect for lubricating engine parts, as it does not run all over the place and making a mess. And the threads definitely need to be lubricated before tightening, as they can easily deceive the torque wrench and misguide you. Thank you for sharing Mr Allen! I'll follow some new tips I saw in your videos!

[@skofflaww3883]

I was taught to use clean but no lube for torque but I think lube would make specs more consistent.

[@duroxkilo]

@@skofflaww3883 it depends on the application/specs... lubricants cause over-torquing if the instructions don't call for prior lubrication. i don't recall the exact number, but it's considerable (say >10%). in some instances the instructions call for de-greasing the parts before torquing (like when gaskets are involved).

[@peter-e2q]

Anyone questioning Allen, knows nothing about him. He can build a bike from bits of scrap metal found at the docks!

[@davidfalgout7304]

@@peter-e2q so true.... next week he will create a v-8 ST1100... resulting in a Super ST 2200! Out of 8 billion humans, he is most likely 1 in 20 that can do what he does!

[@gedofgont1006]

What I love most about these videos is the hushed, devotional, almost church-like, atmosphere Alan generates as he works. No music, no silly effects, or editing. It's not only inspirational, it's also tremendously soothing. Happy New year Alan! 👏👏👏👏👏👏👏👏

[@AllenMillyard]

thank you

[@peter-e2q]

Almost church like atmosphere. I love that description, so apt! The reverence behind professional engineering… and motorbikes !

[@Doug791]

Todays sermon on Honda maintenance will be delivered by ArchBishop Millyard. Hallelujah , Amen. Happy new year Allen and family.

[@CBCycles]

Yes, soothing, Allen is really an ASMR artist posing as an engineer hehe. HNY!

[@tonycamplin8607]

@@CBCycles What does ASMR mean?

[@Boppa1260]

All the very best Allen and Tracey and all the viewers. 👏🏻

[@fidelcatsro6948]

ameen amigo

[@russtaylor2122]

Anyone else feel like they've actually done the job just by watching Allen do it...?

[@ducatobeing]

Watching Allen work is so therapeutic, very relaxing. This gives me the entirely wrong impression that I could go to my garage and do the same things.

[@pauljenkins2501]

" I wasn't happy about the whine on 4th gear, so I bought a replacement gearbox. By the time I was finished with it, I had created a 10 speed gearbox with two levers. They all select really nicely, and It's now geared for about 225 miles per hour. I'm well pleased with that......" Thank you for another lovely video, Allen. The Christmas cake looked very nice, too. Best wishes to you and Tracey for 2023.

[@howardosborne8647]

Perfect....just perfect👌

[@Birky_41]

Am I the only one who finds watching these therapeutic? Great content as always Alan

[@rdaystrom4540]

Very nice video of the crankshaft bearing fitting and transmission rebuild. I love the microscopic view. You're getting so good at making these videos. Beyond professional.

[@AllenMillyard]

Thankyou I try to make them interesting and give the viewer a close up view especially as a lot of people watch on TV’s

[@dord1954]

A very Happy New Year to you and your family Allen, loving the rebuild 👍🎉🍺

[@peter-e2q]

Allen, from the second I press ‘play’ your videos are unmissable until the very end. Purely interesting, well presented, calm, no irrelevant background music (I have Asperger’s, can’t handle ‘mood music’), and all the knowledge and tips of a professional engineer… and biker! I miss having a bike.

[@timboharty7325]

Motorbikes, nature, tea and cake , it doesn’t get any better than that , ( well maybe a kipper bap on Peel harbour! ) best wishes for ‘23

[@AllenMillyard]

Yes kipper bap on peel harbour is just perfect

[@timboharty7325]

@@AllenMillyard perfect day , you was riding the Flying millyard and I was on my T500 highpiped scrambler

[@ai-d2121]

Happy new year to all. The cuppa tea part brought tears to my eyes. Happiness is in little things.

[@mrsmith4662]

It's coming together nicely. It always amazes me that Allen can effortlessley work his way around the inumerable parts of the engine and gearbox and put it all back together perfectly and better than before. I liked the reference to the torque wrench borrowed from Henry - brand new (It's best we keep within our skill sets). Looking forward to the next episode.

[@carleddison7479]

Yes, lovely friendly dig at a mate, "..never used".. As we all do.

[@howardosborne8647]

There's nothing wrong about Henry having a nice torque wrench to look at so long as he knows his limitations and hands it to Allen to put it to work.🙃

[@dennisyoung4631]

I have a 1/4 inch drive version in the bike stand drawers.

[@alanblack9540]

There's a therapy in watching a master at work. Thank you for your efforts Allen.

[@martiniv8924]

Unfortunate that when it was new they didn’t fit the right size bearing, ‘a rarity for a Honda 🤔 but looking on the bright side, now you will have an engine and gearbox that should last a lifetime, and we get to see some new year spannering, and what’s in the cake tin 😀 Happy new year to the Millyard’s 👍🏻😎

[@mikeholt7881]

I bet the Radfems would HATE the fact that Tracey makes your brew to the correct specification, lol! All the best to you both!

[@philipcullen4300]

Don't think I even blinked watching this, and over to soon

[@timceltic6439]

And to think I gave 20 years going to school and I have learned more in your video's 👍👏

[@AllenMillyard]

That’s brilliant

[@thewatcher5271]

Another Thing I Like About Your Videos, Is Your Undying Love For The Machine! Forgive Me If I've Already Commented, I Watch Them So Many Times, I Can't Keep Track. Thank You.

[@scottastell9415]

Thoroughly enjoyable. Wish I could see your video thirty years ago when I mucked around with engines.

[@neilbarnett3046]

I like the fact that Henry's torque wrench has never been used.

[@martinholt2844]

Still is awe of your expertise Allen 👍

[@MarkBrown-gc6hr]

All the best for 2023.

[@ruthjohnson624]

Remember Pan trips to Suhl in Germany . St Johann in Polgau and Evora Portugal . Any one else . This video is so inspirational .. Shot blasted old plugs yesterday and off it went . 17000 miles . Made a coffee with your kettle! . Excited to see end start up . Courageous I think

[@JT-si6bl]

May you all have a wonderful 2023, and beyond. Lovely video. Thanks for sharing.

[@carsyoungtimerfreak1149]

Thank you for this video and Happy New Year. I'm not planning on doing the same with my ST1100, yet your videos give me a good insight in the engine and gearbox, much appreciated. You must be one of the few people who have actually stripped and rebuilt a ST1100 engine.

[@caroldave4037]

Somehow allen i cant see henry using t/wrench too busy watching you and drinking tea...😉🤣best wishes for you and mrs millyard 2023...

[@Quadlaners]

I don't even have a bike but like watching these videos , your skill is amazing you should have your own show

[@davefrench3608]

The quality of that engine is exceptional. From the cleanliness I can see it’s been well maintained. Interesting to a second manufacturing defect - ok the difference between green and brown shells is tiny but you’d have thought that they would have picked the correct shells given the rods and journals are marked correctly

[@paulg3336]

too much sake for Hiroki the previous night

[@RickBaconsAdventures]

@@paulg3336 The brown shell shortage was happening then too

[@monikacognomen1096]

Yeah, great quality. Knackered big end and gearbox on an engine that has been coddled and barely been around the block. I've seen better pit bikes that cost less than the gaskets on this overhaul.

[@RickBaconsAdventures]

@@monikacognomen1096 some owner before him probably held it against the rev limiter for 5 minutes without warming it up every time they rode it, with 40 weight walmart dino oil in the sump

[@monikacognomen1096]

@@RickBaconsAdventures Possibly. Or it was assembled by a fool. Someone who might have put the wrong size bearings in, maybe. We have no evidence whatsoever for your account of why it's knackered, but solid proof for mine if we discount the notion that Allen was lying his ass off. That seems highly unlikely, albeit not impossible. However, I'd go with facts over speculation every time. How about you?

[@marscruz]

Your macro camera work puts us right next to your fingers and tools. What a great way to make us feel included and special. Must have been a Friday afternoon at the Honda factory when your engine was built or a late night before for the assembly mechanic. I hope your transmission work solves the whining problem. I had a Flying Brick BMW 1200 that is somewhat similar to your Honda. Thanks for showing us your meticulous work process.

[@johs9000]

Any motorbike will be in perfect hands with Allen

[@Adem-sb8mb]

We need a shed/garage tour Allen, it is well overdue!

[@jonathansmythe6273]

Nice. The last of our 4 hedgehogs, the smallest, hibernated on the 15th Dec. Love hogs.

[@xpndblhero5170]

This level of attention to detail is crazy to me because I grew up in a small town and people always did things like this half-assed.... I don't think I've ever known someone like this other than me. LoL 😂

[@richchamberlain5327]

Not only a genius mechanic but the tea looks perfect as well 👍

[@JR-bj3uf]

When I built my VTR1000 bottom end the number/letter designation was used to denote big end and main bearing shell sizes. One thing my Honda did add to the specification was an initial big end torque and then a further smooth twist/pull through a given range. Thanks for the video Allen. I just love to watch you work.

[@malcellison8831]

Always a pleasure to watch you at work, Allen. So calm and measured. And so skilful.

[@skofflaww3883]

My new phrase for 2023, “I’ll mend it” referring to your un-mended kettle. Love it!!

[@bobbelsekwol]

I'm very surprised you didn't run a bead of weld over the crank then file it down by eye to make everything fit.

[@ericeller9165]

I could fancy a cup of tea this evening. Perhaps for breakfast this weekend 😎

[@zzzpip]

watching a master at work is like ASMR to me cheers Allen. all the best.

[@billdagoe7371]

I love watching Alan work on bikes. I did my first mc engine when I was about 18. It was the original 1965 Honda 450 4 speed. I bored it out to 500cc's, installed Powroll high compression pistons, Precision Machining racing cams, re-jetted the carbs, etc. etc. It ran pretty good and was a good 2 seconds quicker in the quarter mile (13.23 seconds at Mission Raceways, BC, Canada). Stock was 15.2. The ONLY thing that really bugged me was the 4 speed transmission (which became 5 speed a year or so later). The RPM drop from 1st to 2nd was HUGE! I had to slightly over rev the engine to keep the power band up between shifts. Other than that, it remained reliable until I sold it a year or two later. A great overall experience!

[@nitenurse48]

Pleasure watching a highly professional engineer taking apart & reassembling such a complex engine.

[@ewendavidson8787]

Just discovered your KZbin site. So enjoyable watching your videos. I had a Honda PC 50 when I was 16. Then, like you I had new cd 175. I think it was £336 new in October 1974. I’ve had bikes all my life since. Definitely going to watch more of your videos.

[@martinstone3656]

Perfect tea needs to be in a bone china cup or fine china mug, and for me it has to be Assam tea, mans tea. Always good to watch these in-depth videos.

[@richardbishop1916]

I just figured out what I like about those "Hedge Hogs", As a small boy I had "Guinea Pigs" ! They are both mini pigs ,And cute ! Incidentally ,I remember I put Heavy grease on the drum cam on my H2 after I carefully worked out the perfect shimming so the new parts would shift like a fine clock ! What a mistake ! I Worked late into the night so I could go out in the morning for the first start and ride !, ....It gets cold here, And I had long forgotten the grease on the drum cam ! ,Started wonderfully, A few little adjustments ! Now 1st gear !.........? (rock solid)!.....Oh No! "Murphy's Law"! ( Sweating , Worries,etc.) Then It occurred to me ! Get The Space Heater !. After 2 hrs. of a "Case splitting Headache" (and heating the bottom of the H2) ...OMG ! Thank God ! I really didn't want to take that apart again,I am ready to Ride !. And what a ride ! I felt like a King !, Up comes that front wheel ! I have to show off my new "Lester " 7 spoke I beam MAG wheels and Dual KZ650 Discs (front end)! It was Intoxicating!(I didn't want to get pegged for speeding) Everyone had wire wheels back then !,Honda had pressed steel !. About that Christmas Cake, I was born in 1959 in Toronto Canada and the supply of Rich Tasty Chewy Xmas cake had thinned out here ! ("The Long Search") You should do something special for Tracy (She can and does actually make these kind of literally important snacks!) What would Tea Time be without that?....Merry Christmas and happy new year to You and Tracey...

[@eggbod]

st1100 is one of my favourite ever bikes, i still miss mine, the fjr1300 which replaced it isn't as nice

[@cdnpont]

Watching and listening to Allen assemble that gearbox was asmr to me.

[@firsteerr]

12 minutes forty seconds before we get to what we were all waiting for " what's in the tin Allen " and we were not disappointed !!

[@howardosborne8647]

There are NO disappointing tins in that kitchen🥧🧁🍩🍰

[@drdoolittle5724]

Why do I feel like I'm at the dentist watching Allen so beautifully put everything back together! HNY Allen and Tracy!

[@robertklein9190]

I don't think some dentist really get everything back to original condition at all, hope yours are better than a few I've gone to, I'll try Allen next.

[@howardosborne8647]

@@robertklein9190 Best to avoid the ones with a red and white pole outside the front door💈

[@monikacognomen1096]

Because its painful?

[@yosmith1]

New Allen Millard video series, that makes be pleased :)

[@lesleysmith5623]

Very relaxing video to watch. Why am I not surprised that your ‘friend’ Henry has a new, unused torque wrench 😊

[@NOELTM]

Wow - a perfect start to 2023 with a new video from Allen. I admire your skill and knowledge and the calm way you explain the key steps. Thank you!

[@johnnyknap]

Happy New Year! Fascinating to see inside the gearbox. Always amazes me the the bearing nuts don’t vibrate off with the vibration and loads on them . Those hedgehogs look well fed. Thanks for all the videos Alan.

[@Crustyfox808]

Really love these strip down videos Alan, especially the way you take your time to explain what most expect people to know ( I know zilch about engines and regret not learning about earlier in life , I’m now 60 🫤) also love your breaks for tea, cake and animals…brilliant !

[@paulclarkson1778]

Wonderful stuff. I'm watching, nodding my head and making comments like "thought so" and "of course" even though I've no idea what's going on : - )

[@chrv2956]

Beside the pleasure watching you work on the ST 1100 (I own one my self) I always appreciate you showing your love to Tracy. Thanks for one more great video, and HAPPY NEW YEAR to all the Millyard family from Denmark

[@jamesgraves7091]

Love how you do everything perfect.....even better a strong cuppa tea, uncommon for a English man.

[@jamesgraves7091]

PS: love the hedgehogs

[@iainhannay4530]

Happy New Year to everyone on this channel! Cheers Allen for kicking our year off. Hurry up with those shells.

[@AllenMillyard]

I wonder if David silver spares watched ?

[@scottcates]

I'm a tinkerer and a rider and I have rebuilt a zg1000 engine so I was curious how the Honda V4 engine came apart. I was surprised to see that modular gearbox -- Pretty cool, indeed. But then I finished up the video and started reading the comments and I was really taken in by the nice words of appreciation for both the video qualities, the wrenching, and the coziness of the hedgehogs and tea. These are all good things the world could use more of right now. Cheers to all. Suffice it to say I am now a new subscriber.

[@keitho77]

Thanks Alan. I'm almost tempted to source and buy a faulty Pan European because of this series 😄

[@AllenMillyard]

Brilliant there are loads for sale on eBay

[@rhett7716]

Very Satisfying as usual Allen... Thankyou !! 👍

[@iandunipace]

amazing to watch. you are so gifted. Allen.

[@romandybala]

I once did the same thing. Wore those purple plasticy gloves to change a spark plug on my AJS single. That was a busy day. Needed a cuppa real bad after that.Cant imagine doing 4 spark plugs in one day.🙂

[@hullygully1135]

I have been riding motorcycles (legally) since 1961and also a time-served engineering fitter and it's always an absolute pleasure to watch Alan in his videos, I hope he does not get too distracted with his TV appearances which would be a shame.

[@matthewwirth3295]

Thanks Allen for explaining the bearing selection process. I’m rebuilding a GL1200 Goldwing with the similar main and rod bearing codes.

[@seancrumby3241]

Happy 2023 to you and your family 🙏💓

[@59vaughn]

Enjoying tremendously..hedgehog is quite the darling...

[@thebigandchannel957]

Brilliant vid. Keep them coming. 😊

[@kevinchappell5837]

Henry with a torque wrench, never thought I hear that, ha ha. Ah cake good work.

[@AnIdiotOnTwoWheels]

The year just started and it's already a good one 🙂

[@assessor1276]

This is so interesting because as noted on the ST Owners forum, a rebuild of an ST1100 or 1300 engine is virtually unknown. It is also fascinating that you have found what appears to be an assembly error right from the Honda factory! Happy New Year to you and yours Allen from Harrow, Ontario Canada.

[@AllenMillyard]

One of the reasons I took it apart , to be fair it ran well and rode nice just had an annoying knock as I was pulling away 🤔

[@monikacognomen1096]

@@AllenMillyard I'd call big end knock and a whiny gearbox almost a definition of a poor running engine. In fact, the word I'd use is 'knackered'.

[@briannicholls187]

Your explanations and attention to detail is excellent Alan. I look forward to all your outstanding engineering videos, please keep them posted. All the very best to you and lovely wife Tracy for the coming year

[@graculuslurcher380]

I changed the main bearing/con rod bearings on a 76 cb 750 a few years ago, being used to old brit bikes with less accurate fits shall we say, didn't realise Honda tied them down to microns, couldn't find some of the sizes/colour codes, was told to take a midpoint size of shell, (guess) never had any problems when built up. I was told the accurate sizing is more for racing engines. When I sold it, found the missing sizes below front of engine. Amazing

[@leedavies839]

I look forward to these videos. Thank you.

[@WiltshireMan]

Good news on the new Kettle Allen, that is a very important purchase, where would we be without a kettle to make a cup of tea and it was nice to see the hedgehog out for a Winter's snump around your garden. The bike build was alright too. Looking forward to seeing it complete and up&running:) Happy New Year Sandy

[@tonycamplin8607]

All of the best to you and Tracey for 2033. As usual a really great video showing off your fantastic skills and attention to detail. However I don't think that you could do any it without Tracey's kitchen skills!

[@delmonti]

a real craftsman at work, its a delight to watch

[@ruthjohnson624]

Well done indeed . Mines 17000 miles so I'm glad I can just watch you. Music ,no need,altho Bach Brandenburg concertos would go ok . Remember Pan Clan trips to Austria and Germany

[@RanDomRikM]

Another great video Allen, created in your own unique way👍🏻

[@hlpang1075]

Brilliant!

[@bubster1981]

i see a lot of people pulling on torque wrenches with a target of lets say 25 ft/lb , they'll stop very close of that like 20 or so & then magically the next time they return they get a 25lb click...a mechanic i worked with yrs ago always said to make sure it comes to torque in the rotation, never forgot that . Your torqueing looked good lol

[@jjcale1976]

Last old Japan. This engine is a work of art. It's a pleasure to see such a solid piece of steel and aluminum. Well done Honda engineers. They save a lot more now. Thank you very much for the videos!

[@reverendhoover]

Fascinating and amazing attention to detail. Can't wait for those shells to arrive!

[@l.j.b9863]

Allen your a national treasure, I am always astounded by your knowledge, and your çalm way you approach everything. No fancy tool chests or top of the range garage, just pure skill and a love for what you do. Happy new year to you both, keep the videos coming.

[@staylofordo7111]

Nice build. I was taught by a two old fashioned technicians, standard torque rating for bolt or nut type fasteners, always use lubricant to insure correct clamping force. SAE . My dad was meticulous on clean and proper lubricants. I was pushed for time when I was at Barber Motorsports and did not have time, but I look at your bikes there on our next visit . Thanks for the video!!

[@anthonym2277]

I never see seen a Japanese bike with a seperate transmission case, that's cool

[@simonr1392]

Fantastic video content as always. Great footage with clear information as to what you're doing at all times. A true master engineer with passion, willing to show everyone else. 😁

[@sammorgan2390]

I enjoy your videos immensely

[@titubatu1]

I'd love to see an ST with a 180 degree crank. If anyone can pull that off it's you... :) Thanks for the videos!

[@robinbrowne5419]

Happy New Year Allen, Tracey and Hedgehogs. PS - If Tracey was truly psychic she would have hidden the cake away BEFORE much of it disappeared.

[@Chr.U.Cas1622]

Dear Mr. Millyard. Before I even watch another one of your great videos: Happy new year to you, your family and friends. Best regards, luck and health in particular.

[@tonegeerkins491]

Thanx Alen, another blinder.

[@wiratwainwright7717]

Really informative and covers everything at a good pace, I like it.

[@1234567marks]

Nice work as always Allen, glad to see it’s not just me that finds it impossible to wait until I have all the parts 🙂

[@terrysmith7076]

You are brilliant Allen great videos. Thank you for sharing ☮️

[@nickronin9618]

Allen the Wizard! happy new year to everyone.

[@Jestersson]

Brilliant video, can’t wait to watch the rest!👍

[@petecurran3995]

All the best to you both for 2023 - always look forward to the further adventures of AM &T!

[@GoinDownhill361]

Allen tinkering. Nice way to start 2023. Happy New Year everyone!

[@kerrygleeson4409]

Thanks Allen always a very interesting project