Kawasaki Z1B 900 engine rebuild - Episode 3
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- Опубліковано 8 січ 2025
- In this video im reassembling the Kawasaki Z1 900 bottom end and fitting the pistons and barrels. I have left off the starter motor and alternator for the time being to reduce weight of then engine to make it lighter to lift back into the frame. The weather was a bit wet and windy so I was in the garage for the length of the length of this video, so there is no wildlife interludes this time, but they will return.
I hope you find the video interesting.
Best regards
Allen
I find it mesmerising watching Allen at work, so calm and precise. These would be the gold standard of training films for aspiring mechanics ☺️
Can you even imagine putting the circlips on the pistons without rags covering the case!?!
@@blacksquirrel4008I was thinking that. Just rebuilt a Subaru EJ25 this summer and you cannot place rags under and it was circlip finding hell.
@@blacksquirrel4008 Yes, done it myself and never dropped one. They are very easy to fit if you do it right, holding them with one thumb while pushing the bottom up and in, just as Allen did.
Huh...and the notion of "assembly is the reversal of disassembly" is tossed out, just like that... ((haha))
Thanks Allen
So very true!
Is it just me or does anyone else find watching Alan’s videos extremely relaxing? ☺️
I'm sure there are thousands of us who enjoy the videos Allen makes, not many people can do this 😊
I had to watch it a second time.....he sent me to sleep halfway through the first time while watching 😴💤
Allen and the art of motorcycle maintenance.
Yep ❤
@@howardosborne8647 It put me sleep too 😂! I mean it in a good way , he has a very soft and relaxing voice . I got a good excuse to watch it again 😂😂😂
Even after all those years, I am still impressed with how much engineering went into that engine.
I am the same, the Japenese were late to the party, but when they came in WOW,
True marvels of engineering.
Seeing how strongly they’re built, it’s easier to understand why these engines did so well in drag racing.
I worked for a Kawasaki dealer back in the day, uncrated so Z1A and Z1Bs.
The writing was well and truly on the wall for the British motorcycle industry when Honda introduced the CB750 four....it was a sign to turn the lights off when Kawasaki followed with this gem of a bike.
You are the living embodiment of Zen and the art of motorcycle maintenance. If you made a video of you sweeping up your shed, I'd watch it. More power to your elbow, Allen!
Well spoken. I wonder if he's ever raised his voice at anyone or anything in his entire life..
@@CONEHEADDK : Well, there was one video when he raised his voice ... over the noise of the engine in a test stand, no mufflers fitted
... and look at the satisfaction shown al over his face - boys and their toys 😀😀
I totally agree with all the comments, admiring the zen and technical competency. And as stated above, I would watch his video of cleaning out the shed 🙂
@@chrissein632 :D I would watch it too - even though there practically wouldn't be anything to sweep out, it seems.
I still believe that Allen and Tracy ought to be Lord and Lady Millyard.....
When you see some of the idiots who are given Knighthoods.... Why can't we take the "Honours List" back into the hands of the people who deserve it??? Allen deserves it for his British Engineering Ingenuity and he is well known throughout the World.... And Tracey deserves it for her amazing Cup cakes and for feeding the birds and hedgehogs 🦔 😁👍😁
Could NOT AGREE MORE with You on that one My Friend!!! ; >)
I agree, also, and mention it When Tracey's hand appears with the mixing bowl, and the wildlife, Tracey is a bit camera shy, as ive never seen her
Allen Millyard MBE - Motor Bike Engineer.
@@markmiwurdz202 or OBE, Outstanding Bike Engineer
WELL SAID - what a team they are!!
I want to rewatch all of Allen's videos to see how many times he says something is perfect. He says it a LOT, but there's no exaggeration. He simply does everything so incredibly precise.
Feeling like crap.aching all over,headache, have a cuppa and watch this man doing his thing..........some kind of therapy takes place...me feeling better,thanks Allen.
Cant believe you didn't put a rag over the bottom end when fitting those circlips Alan ... you really are a magician it seems 😊
I had a go at him for the same thing on an earlier video. It was one of the "golden rules" in the old days. You drop one circlip down the crankcase and it's time to rip your hair out!
As always I give a nod to the people who designed and manufactured that engine, they’re on another level to us mere mortals 😊 very enjoyable watching this being nicely rebuilt 👍
And that wasn't done on a screen, that's what I was thinking.
I agree. And yet erstwhile “intelligent” people believe in evolution which assumes the human body, a mass of soft tissue motors which regenerate themselves for a lifetime has no designer....just sort of evolved. Loved the vital close tolerances in this motor.
@@peternicholsonu6090,Behold , the Oracle speaketh!
@@peternicholsonu6090 Not the time or place for preaching. An engine is nothing like the human body and your beliefs on evolution are nothing to do with what we just watched. Keep that stuff for church.
At 10:00
,that tweaked a nerve😂. As a keen and impatient 15 year old in the absence of my father who was still at work,I decided to start rebuilding the honda 125 engine I had seemingly been waiting forever for a con rod for.I was feeling pleased with my self,now having most of the bulk of it together by the time he arrived,only to be shot down in flames when he immediately pointed out that a part of the kickstart mechanism was still on the bench. Thanks Allen for the video and the painful reminder👍
It makes it seem more like a real 'racer' if you have to bump start it every time 🤣
Allen, you work as calmly and as focused as a surgeon, and make a complicated assembly look very simple. I'm surprised you use no gasket cement/sealant on the paper gaskets. I can't picture the engine not seeping oil. I also didn't see you torque anything to specific values. Watching this assembly makes me cry for my 1974 Z-1B, wishing I still had it. Given the choice of any motorcycle I ever owned (including the 900 Ninja), I'd love to have my Z-1B again. Eagerly awaiting the next episode.
Allen is our Bob Ross for motorcycle engine assembly, using a simple palette of spanners, ratchets, and screwdrivers for brushes on a mechanical canvas to teach, inspire, and achieve an artistic satisfaction and inner calmness...
I like and his voice to Bob Ross myself 😀
Rebuilding a 76 kz 900 right now. Your videos have been a great source of information.
It's satisfying to see Allen using JIS screwdrivers, but of course I expected nothing less from the engineer who always does everything "just perfect".
This is literally a labour of passion and massive knowledge, we all have rebuilt engines, marine/ industrial or the like as a job.
But for this man it’s different, he’s an absolute genius and I’ll always stand by that comment.
He loves what he does/ he’s not rushed and boyy does he get it right. What an engineer/ machinists and a second to none engine builder
All done without a torque wrench in sight, Allen has the calibrated wrist, well done that man.
I do enjoy an unexpected Millyard popping up.
Allen is a master who can get the bolts into the right torque without saying "click".
I’ve programmed my torque wrench to moan instead of click. I’m really pleased with that.
You make fitting those barrels look so easy👍🏻
Classic engine being rebuilt by a classic guy .
No sign of a torque wrench during the rebuild. Alan is a marvel.
It was worth getting the engine vapour blasted , it looks amazing.
Very hypnotic. Nice to see someone else who applies oil for oil seal installation. Not many folk I've worked with bothered. Half jobs. My first bike was a raced & rallied to within a inch of it's life and then some Fizzy. I spent more time pushing that bike than riding it! I rebuilt the engine swapping the barrels out for a 75cc kit. After the rebuild was finished I started the beast up and went scooting off down the road. 1st, 2nd, 3rd, 4t..... 4t....... 4th?!? I couldn't select 4th gear so it had become a Tizzy!! I pulled up back at home and scratched my head for a while. I checked everything out and it all seemed fine. I went and sat at the table and noticed this gear on the workbench staring back at me.... yep 4th gear! Have fun
If I were Charles I would Knight you for all this.
What I love about Allen is that he doesn't use a torque wrench simply because he knows what he's doing.
I'm sure he does for some things. Sure as in "I bet".
@@CONEHEADDK Conrods would be my only bet as it's pretty much the only thing I use my torque wrench on these days.
@@vitjakes5531 Cylinder heads perhaps.
@@CONEHEADDK It remains to be seen on the next episode. But I've done a fair share of heads without a torque wrench, too. :D
@@vitjakes5531 Succes can be achieved by luck. I prefere to use the advised control. God knows I ruined lots of things from not knowing enough, when I was "a kid". Maybe if my dad hadn't been a narcissist piece of knowitall poop, I would have been taught something about accepting ones limmitations. :)
It's therapy to watch this stuff. Wow
Thanks for all the work you put in for us Allen.
I can’t be the only person to think those engine castings are things of beauty.
I like to think Allen has evolved so far beyond us mere mortals that he doesn't need a torque wrench when rebuilding an engine.
Dear Mr. Millyard-- Kawasaki owes you a pension -- your expertly produced, lit, and arranged videos put their service manuals to shame! Fantastic as usual.
So refreshing to see an engine rebuild with no impact wrench in sight. As is said “slow and steady win’s the race”, and makes for a easy watch 🫠👍
The most amazing thing about this whole build is that you still have the 10mm socket, legend 🙏🤙
According to the clock he started at 3.55 and finished at 4.16.....21 minutes?? What a guy👍
So therapeutic, watching Allen assembling it so carefully and precisely.
Meditation.
I love motorcycles, all motorcycles, and recently I have been looking into film making. Your videos make me appreciate how much effort it takes to get the shots that you do, and your voice is very calming and easy to listen to. Thank you for documenting all the wonderful things that you do and sharing them with us.
Great video Allen, I always enjoy watching fine work being done in a tidy workspace, and your commentary is top notch. Thanks for the video!
Invaluable content for rebuilding my '78 KZ650 that was given to me with holes in 2 pistons.
The Z1B 900 and Z650 engines are iirc almost indistinguishable internally. This video is gold reference material for any of the DOHC air cooled 4 cylinder Z engines.
fantastic step by step guide to rebuilding and engine. Have a 1974 bike which is in a total state of disrepair and these videos instil confidence to take the task on. Thanks Allen
Cheers Allen. We are fitting the barrels to a Honda CL450 this weekend, that wooden support under the piston skirt should help things on end.
The beauty of roller bearings on the crankshaft. The crankshaft can be turned with almost no effort.
As always, an excellent job. What I love is the way Alan effortlessly assembles the thing with never a reference to any manual.
That clutch cover is a thing of beauty
Can’t say enough about how calming it is to listen to Allen as he assembles an engine 👍🏻
just like going for therapy watching Allen do it allin his stride !
You're such a perfectionist I absolutely feel like I could rebuild an engine after watching you
Allen, I've has so many motorcycles that I should have kept. Your videos always bring a smile to my face; and the video is so much more educational. On a side note, I learned to read from motorcycle magazines. Thanks for your efforts!
What a wonderful mechanical puzzle!
If only MMI would use Allen's videos as their training vids,more students would be able to grasp a full engine and tranny teardown and rebuild,plus see what imagination and hard work can achieve .
I still get blown away by how he can just reassemble an engine so easily without instructions and every bolt can be done the whole way by hand.... I've never been able to do that without scraping a bunch of grease off just to find the bolt holes let alone use the right bolts for each thread. I'd be looking in an old coffee can full of bolts and washers just to find a bolt that was too long then using a stack of washers to take up the slack.... He's just living in luxury w/ his flawless threads and none-stripped screw heads, it's almost unbelievable. 😂😂
The Allen Millyard school of torque setting by experience, respect🙏
The expression "elegant simplicity" comes to mind 👏
Hello Mr. Millyard , always a pleasure to watch you spinning spanners...!!!😊
The trans and crankcase were in fine shape inside. Very nice assembly! You must be ready for a cup of tea now. Cheers.
This is like watching a peaceful stream running through a meadow. Utterly relaxing.
I love the way Charlie doesn’t say a word while the build is in progress ,it looks like it’s all sinking in though 😁
Thank you, Allen. Your videos are most informative and entertaining.
I can barely undo a bolt without it leaping out of my hands and having to chase it all round the garage floor, so to see mastery and engine knowledge of this level is an absolute treat. Can't wait to see the finished bike and hear it fire into life
I’d bet every time Allen works on an engine, he’s pondering the many ways he could improve it’s power and efficiency.
Murphy's law does not have a chance against Allen. I held my breath when he installed the piston circlips without rag in the crankcase openings. 😀
I could watch and listen for hours.
Always cheers me up, when we get a new video from Allen, the gold standard in engineering, another cracking video from obi wan.
Well. Those hedgehogs stayed up late watching the engine assembly.
Must be pretty tired after watching that dazzling engine !
Trinidad & Tobago.
West Indies.
Let me know when you 🔥 her up Allen I'm sure I will be able to hear it from my back garden! Can't wait to see it finished. 👍👍
Thank you Allen for another excellent class, I'm enjoying every minute because I restored a 1978 Kawasaki kz1000 "A1" and I learn more in each of your videos.
Hugs from the south of Brazil
Thanks For The Upload, Allen. I Just Wonder How Many Kawasaki Engines You've Rebuilt. You Must Have A Fantastic Memory. Can't Wait For #4!
just a few I guess
The mechanical competence level of this man is off the scale!
Great entertainment Allen, fantastic work. The engine will run better than new after your fettling. Well done.
Let the good times roll
An honour to watch the master work.
Those Engine Castings are a work of Art.
Sir Allen_Millyard, your work is like a symphony. Not a workshop manual to be seen.
Just brilliant Allen, so looking forward to the next video. 👍👍
Allen is hard for you not to add a cylinder here or there while assembling. Another blinding video 👍
Better than new. That's one rebuilt engine you wouldn't have a second thought about...the 'was it done properly?' thought !! Lovely work Allen 👍
I found it very easy, to sit here and watch, not sure how much i remembered let alone attempting to rebuild a Z1 engine and gearbox
I love the "old school" torque wrench application, ya know when it's right by feel. It looks s simple. Loe it.
For the first time ever, no cupcakes were harmed in the making if this video!
Loving this series, Allen. Just a joy to watch. Thank you!
Brilliant Allan I can watch your videos over again thank you 👍
Appreciate the time you put into these videos Allen 👍 Look forward to many more! 🤞
it does take a while all shot and edited on my iPhone
@@AllenMillyard I just bought one. Can you suggest a "Create perfect videos with your Iphone for dummies" video? I can barely turn mine on without help. :S
Absolutley fascinating to watch Allen so calm and no sight of a manual anywhere. It astonishes me how you can still get all new parts Gaskets, Seals and Cam Chains etc for these bikes 👍
Master mechanic at work, what a brilliant how to guide, Thanks Allen
Great to see proper old school engineers like yourself using mechanical hand tools. So many today use electric or pneumatic drivers for undoing and doing up the bolts and nuts. 👏👍
Takes me back to my youth, rebuilding GS 1000 tuned engines in the shed.
So relaxing to see calm and precise job on this marvellous Kawasaki engine
I get the feeling that it is rare in a Millyard rebuild, that you scratch your head and say "I wonder where this bit goes?" 🙄 Always in awe of your work Allen 👏 xo 💕
"Niiice - extra parts left over".. :D
Beautiful video ! I'm about to start on a Z650 engine, so I know that any time where Allen says "this can be a little bit fiddly" I should allow for half a day of struggling, spitting and cursing, accidentally stabbing myself with sharp pointy tools and trying to find bits that spring-launch themselves away from the engine or (even worse) drop inside :D
Nice job Allan, you make it look so easy, and no extra cylinders this time. 😂🤣👍
Thanks for the video Allen. Such a beautiful piece of engineering. 👍
Welldone Allen, It is always nice to see an engine being rebuilt like this with everything nice and clean and organised :)
I love watching you work Mr Millyard, so cool. Please keep it going. 👌👍
Thank you Allen for sharing this build with us. Cheers
Cannot wait to hear his engine running, oh the memories....
Watching a routined master putting together an engine has a zen-like quality to it. German ZAMs Channel is equally good there, albeit a bit more humble with his projects. ☺
That was great! 🤩
Allen, that was mesmerising! Such great work! Can't wait for it to fire up. Thanks, as ever, for posting, cheers, John.
Watching that engine go together was a thing of beauty
5,000 views in one hour (at the time of this comment). What does that tell one? Respect.
It's always so giving watching someone who masters their craft like Allen does. Even the soft clock in the background calms me down. Thank you Allen for putting out videos showing us a masterclass in machining work, free of charge no less. God bless and lots of love from Norway.
edit: No cake or cupcakes in this episode Allen? Wife on holiday?😀
Out shopping again 🙈
I love how Charlie Weaver is always watching
Watching you work is like therapy without the cost, thank you Dr Millyard.