How I changed the crankshaft seals on my 1970 Kawasaki H1 500 triple
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- เผยแพร่เมื่อ 27 ก.ย. 2024
- In this video I show you how i changed the crankshaft seals in my 1970 Kawasaki H1 500 triple. I used my Sykes Picavant bearing extractor, Permatex Ultra grey gasket sealer. The inner crankshaft seals came from CruzinImage in Japan, New engine seals and gaskets came from Z Power Kawasaki UK and friction reducing oil from ZX1 Extralube. The job was delayed half a day when i hit my thumb while truing the crankshaft with my 2kg copper hammer! but i was seen by the excellent staff at my local A&E. Thanks to my son Stephen who helped with the tracking shots at the end of the video, check out his Instagram at stephen_millyard.
Pops into the shed and rebuilds his bike engine. All done it a few hours. Yes really. Allen is the master.
The guy is an awesome technician would let him work on my bike anytime his skill just amazes me
guru‼️®️™️
@@dobermanguy9437😊
He should use the torque wrench 4 the bottom end tightenint nuts ...
The only channel where I bother to watch the ads as I like to think it helps Allen a tiny bit. Thanks for the information and entertainment as usual.
There is something quite satisfying about watching you pour new oil, into a freshly built engine, or indeed assemble machined or cleaned parts, such as the sound the head makes as you place it over the bolt stems. Love your work Allen, please dont stop making these videos.
Allen, I can tell you my trick for putting bearings on using a incandescent drop or inspection light. Just put the bearing on the bulb and in a few minutes the bearing bore expands and just drops onto the journal of whatever you are putting together. Worked for me a many a years. I love the rotary phone that you use. Nothing like old technology that still works fine. The attention to details using the brush to apply the sealer is just great. This keep excesses at bay from clogging the oil holes and other things. I was always impressed with the Japanese attention to details on assembly fit and finish. The copper annealing method is something a lot of people miss and have a slow leak and or seep too. This brings back some real nice memories of how much fun I had with my 750. Man oh man did this bike fly for sure, but a bit squirrely in the braking department at high speeds. Thank you for bringing me back to 1977. That was a great time for a many of us young men. Something the young generation does not understand. Nice video Allen !!!! Peace and stay virus free fella too. VF
I use a hotplate and a pot of oil to put bearings on
@@enduser6982 I use a drop light with the shield removed. The rough service incandescent bulb of 2 hundred watts works perfect. Just place the bulb inside a safety can with a flip lid top, foot activated. Just place bearing on bulb and wait 2 to 5 minutes and just place onto journal. Hold for few seconds and your done. V
using my surface pro, i watched this amazing video, and it was perfect, i'm well pleased with that.
Im surprised you resisted the urge to add another couple of cylinders while you had it apart. :)
A 5 cylinder would sound amazing! It’d probably be quite a tricky crankshaft build/balance though!
No extra cylinders added? what is this heresy!!
@@Jonathan_Doe_ Allens been there, sold that!
@@Jonathan_Doe_ ive made around 10 five cylinders based on the triple
Only because he hurt his thumb this time. :)
As a mechanical engineering lecturer, I really admire these videos Allen, also the attention to detail.
His explanation about his details make sure his audience is riveted
yea my dull sunday sat at home nursing a broken hip and sholder is now way better watching a master at work
at least you didn't smack your thumb with a 4 lb+ hammer (~_^)
did you highside or something?
@@jpkalishek4586 i was out on the path an just tripped up in my floppy slippers
What a coincidence! Really!. My hip was broken and the shoulder was dislocated over a year ago. Still waiting for ops (slowed by Covid).
Heal Soon
@@ododargo oops
well, don't do that. it hurts
I do try to be helpful (~_^)
Heal fast!
Get rid of your TV licence, and just watch this channel. No doom and gloom here, only positive can do attitude. Well done, your a proper role model.
I did just that 2 years ago ...never regretted it !!
BEST DAM DECADE OF MY LIFE! Nothing BEATS the SIGHT! SOUND! & SMELL! Two Strokes 4 EVER! God Bless... 😊😊
"line them up, just by sight", as always, you make it look so easy!
To within a thou!
Yeah, but we BMW owners get the additional pleasure of shelling out hundreds of pounds for the special tools needed to do complex maintenance tasks such as checking the oil level in the final drive or inspecting the spark plugs..
"and it fits perfectly"😀
Wow blown away by this video!! This is why I cut the cord on my cable TV last month after 35 years!! Nothing even close to this on US cable channels!! TH-cam is lucky to have you!! Just subscribed!! Thank You for sharing!!
Watching these videos and taking in the mastery of Allen's passion it's easy to overlook the amazing camera footage. Well done on both!
true, the camera job is also a masterpiece
I enjoy his video so much I'm not even disappointed it went together with the same amount of cylinders as when he took it apart.
A squashed thumb doesn't even stop him! Just awesome dedication, skill, knowledge. A pleasure to watch your videos. Thank you for making.
Amazing work and the confidence in being able to put the gudgeon pin circlips in without any rags stuffed down the crankcase in case they fall in there is astounding!
Good to see that even geniuses are human though and can sometimes hit their own thumbs, I guess we've all been there at some point, painful!
Great stuff Allen!
Your videos are so satisfying to watch, Allen. I felt highly accomplished after managing a valve adjustment on my vstrom. Disassembling a crankshaft? Yeah, no.
In every video in which I have watched numerous times is the words,it worked out just perfect, and just by eye. The guy is master, as the Japanese call in the motor industry a Takumi.
Ha! I was just thinking about changing the bearings of my triumph triple crankshaft, and at precisely the same time, this notification came up!
Well done to Tracey for her outstanding camera work.
It was my son Stephen 🎥
@@AllenMillyard Figured that when I spied the ST parked on the road side.
I love the exposition in the phone conversations, someone needs to do a montage of them. Priceless...
That waiting for the rotary dial to cycle, though...
Finally, something us mere mortals can imagine doing ourselves
Okay I take that back
I'm sure you could do that hitting your thumb with a hammer thing.
@@Stephane1995 Yes, untill we attempt doing it!
Yeah, 'imagine' being the operative word...
I'm (fairly) sure I could take the engine completely apart, though I don't have a hydraulic press for dismantling the crank.
Putting it back together, with no pieces left over and everything working right?...
Just completed three 2 stroke twin crank rebuilds and now feel confident to tackle the kawasaki triple crank in fact thanks to Allens excellent video work with advice on scribing the webs and using a set square on the press I can see how a 4, 5 or 6 cylinder crank is feasible. I also found using the bed of a lathe or mill as a flat surface to place a crank on and "see" any misalignment or check with feeler gauges for differences between webs before wielding the copper hammer helped me. 6 Hours to do the first crank 3 for the next then 30 mins for the last one. Thanks for your brilliant videos Allen Putting the con rods on with "Made in Japan" all one way is now compulsory (made me chuckle as I did it, and I thought I was obsessive! ) and I kept my thumb well clear of that hammer, it was making me wince so I think you saved me an A&E visit too!
I always like my rods facing the same way it’s just looks wrong when I see one mismatched 🙈
His press squeaks !!!!!! He’s not perfect, I’ve sussed him !
Seriously, confidence and getting on with it, the secret of life.........
I had the same red H1 in 1970 and I tore it down as well. I did have expansion chambers made for it which helped it a lot. The front brake though was very weak and scary....Nonetheless it was a fabulous bike at the time! Of course I bought an H2 the moment it was available and I brought it in the cargo hold on my flight back home to Italy. It was the first H2 in Europe and caused a big stir wherever I went. These Kawasaki Triples were tremendous fun!
Always amazed by Allen's knowledge, just the little things. Looks at ruler "Tap it once in the high spot and it will be aligned". Bosh!, "Perfect". 👍🏻
Wow, That's The First Time I Saw You Make A Mistake! But Since It Was Just Your Thumb & Not The Bike, It Doesn't Count! What A Great Bike! You Are Livin' The Dream, Man! Thank You.
Properly set up 2T.
Very little exhaust smoke.
Superb.
Properly set up they don’t smoke, with modern oil the pump can be backed off really lean with no problems
Allen Millyard Not only is it putting out very little smoke, it sounds amazing!
Someones actually paid to put a Yamaha RD350 through a compliance test London for the London ULEZ.
It passed! ...because 2 strokes put a lot of oily fumes, but set up right, they barely produce any NOx thats the current obsession!
@@Jonathan_Doe_ That is so true
@@AllenMillyard Allen,love your dedication & mechanical know how that’s 2nd to none! Question,approx how far would you rec I can back off on oil pump adjustment on my stock 1975 H1F? I run proper 98 octane leaded fuel along with top of the line semi syn or full syn Belray or Amsoil injector oil. I read to reduce oil smoke that Kawi legend Tony Nicosia used to unhook the throttle cable from the oil pump letting sit seated in idle position all the time and then added only 1-1.25 oz injector oil per gal fuel which reduced oil smoke a lot on the stock Kawi 500’s he was testing. He said he drag raced a lot with that setup along with also doing a lot of very spirited street riding including some fairly long distance high speed cruising too with not 1 oil related issue and much less oil use & smoke too. So please let me know what you rec I set oil adjustment to reduce smoke or if you think I should simply do what Tony did setting pump to idle position all the time & maybe to be safe add a min of 1.25-1.5 guality injector oil per gal of leaded 98 octane fuel ? BTW, I have been wrenching & riding many different mfg’s bikes for over 50yrs but as far as Kawi street bikes go I have owned 1-350 triple,5-H1’s,1-73 H2,2-76 KZ900’s & 1-77 KZ1000 with 1 900 & the 1000 being bought brand new. Thanks in advance for your help & Happy Safe Motoring to you in the UK! (?)I am located in the USA. Scott
True craftsmanship and precision. Beautiful job.
Allan that thumb bandage looks like something out of a cartoon. You must take care of yourself old Friend, so many "garage builders" look forward to your videos.
As always a gorgeous bike.
annealing the copper gaskets is so smart, never thought of it, great tip.
Yours is the most used BBQ in the UK !!
How else do you build a hot bike ))
And never seen a bit of meat lol
reminded me of re building my CB 160 Honda back in 1971, I had the engine case in mom's kitchen sink and the hot water made the bearings fall out . bit of a surprise but no issue.
@@radioguy1620 I once heated up my BMW R75/5 gearbox in my parents oven to get the bearings out. Glad they where on vacation. Man, that oil stinks! LOL
Thank you for the video, the, Tipps, the beautiful bikes. You are a specialist. I also like the pictures in your garden, the animals, because life is everything
I always hate it when the made in Japan doesn't line up nicely inside my engine!! Such attention to detail!
Hope your thumb's getting better, mate!
Allen's videos always put me in a meditative state.
Great stuff
Love that!
Allen, old bean, you warm my heart watching your meticulous work. I owned one of the first H1's in Savannah GA in 1969. I rode that machine everywhere - all the time, rain or shine!
At 12K miles, the piston slap told me I would soon need to visit the top end for a rebuild. I bought the parts from Cycle World on highway 17 where I bought the bike and did the work my self over a weekend. I opted to install new clutch plates at this time also. Constant wheelies stretched the heck out of every chain I put on it, as well as the drive and wheel sprockets! Oh what fun I had as a young man of 18 spinning wrenches on my own bike. Watching your video just now brought back SO many memories I had of tinkering on my first Kaw. Thank you so much for your very thorough videography!! BTW, where do you find so many Kaws in such excellent condition?
I was just about to lobby my local MP about the lack of posts on you tube by the honourable Allen Millyard and then this was posted!!! and it's a 500 triple OMG!!
My favorite bike was my KH250. Last time I saw it was when I was being loaded into the back of an ambulance, it was lying on the floor very broken ....
I love how you titled the video. You actually rebuilt the whole engine! Wow. Just amazing. I just hope one day I can become as efficient as you are.
Allen, you would be surprised how many people don’t know what a JIS screw driver is!
I dont
I didn't. Had to Google it. No wonder I've messed up so many screw heads...
I do now, have known for a while. But...wish I knew in the 70s when it would have saved so much butchery! :)
You can tell a persons age experience and ability, when they do not need to use a torque wrench or other power tools. Everything by touch feel and sight. Great engineer and video.
Another very informative video from you Allen, I have put a good hydraulic press on my wish list, along with a decent size gas barbecue, tig welder, and a larger milling machine! You honestly prove you can do anything if you put your mind to it.
It looks like Mrs. Millyard is better with a camera than Mr. Millyard is with a hammer. Joking aside what was really great to see is that these classic still have have a life for the foreseeable future, providing you can find a competent engineer. I’m sure videos like this help.
Shhhh the multiple cylinder two stroke street bikes brings back memories. Your braver then I, I always stuff a clean rag in the bottom end incase the "gudgen" lol pin clip decides to drop into the bottom end. You didn't show checking the top end tolerances? Time constraints I guess. I thought I heard a little piston slap? Hmmmmm . Great video on the lost art of two stroke rebuilds. 👍
M&C Doherty, do you mean the piston and bore diameters?
You dare to question the engine building skills of the great Allen Millyard? Heretic!
An expert filmed wonderful rebuilding job !extremely impressed ! thank you I owned the same bike in 1979, but it bit my butt(could not stop to avoid a car who pulled up in front of me……), its an extremely wonderful noisy bike
The bottom case half is a great casting.
You're a brave man Allen fitting gudgeon pin circlips without a rag in the crankcase mouth! :-) I had a circlip fly into the bottom end of my first bike, a C50 and couldn't be bothered to strip it down to retrieve it so just left it there. A few weeks later I was buzzing along when the engine suddenly slowed, made some graunching noises, and then just picked up again and never felt any the worse for it. But ever since I've always stuffed a rag in there when fitting the circlips.
7:03 Everybody under the age of 25 - that kind of telephone was used for 40 years..
an you were mostly confined to the kitchen..8 feet! LOL
No joke,- I gave mine yesterday to a kindergardener to use it as show and tell to the kids! Now I feel like an old hag. lol . I found a package with Mon Cherie Schnaps chocolate cherie thingies with a thankyou note... &ate them ALL! and then had to go to the Doctors cause my pills where empty ! I had a chocklate mouth but was somewhat Wthell-idcare-Corona -fucked up ... but happy. Even the doc didnt gave a fuck and just handet me the receipt as I went out the door with the paper towel roll that stuck somehow to my Ass. I just sat one effin minute on the edge of the
diagnosis bench ya know?
Total Clowns Day Yesterday... .lol . So... shit just happens guys! Yáll get better &stay healthy;-) Greeting from Germany :Beware The Telephones ,-they are tricky...
I love the rotary dial telephone at 7 minutes. Great video, makes crankshaft work seem so easy.
For the life of me I cant understand why there isn't a barbecue in every engineering workshop.
Thank you Allen for a great video! It took me back to when I rebuilt my 71 H1 many years ago. Hearing that sound again was a real treat! I'm still looking for a 71 Norton 750 Combat. I had one with 5000 original miles on it. I had to sell it when baby #3 was on the way, but it was worth it. I think it would make a great retirement project.
14:20 Allen: Puts piston in , then pin followed by circlip
*Me: Put piston in, then pin and drops circlip down the crankcase*
Always stuff the crankcase mouth with tissue or rag before wielding circlips, dont ask me how i know!
@@slartybartfarst9737 been there. Fortunately we'r young just once, rt ?
never thought the excess squeezed out gasket sealer would clog the oil galleries, thanks for that tip.
Allen..You bleed red..throws my theory you were a relative of a vulcan (spock).You make
engine building look easy...Cheers1
I was amazed back in 1972 when my Mach 3 would power wheelie in first gear just rolling on the throttle. It was a real thrill when that power band kicked in. The handling wasn't all that bad as long as you didn't go crazy in the corners, then again most of the Japanese bikes of that time felt like they had a 'hinge in the middle' on bumpy corners. Great video; taking a crankshaft apart is rather intimidating.
Man I remember that sound all those years ago, the 500 sounds just like the KH250 I had,I still remember the day I sold it for a song and nearly ran after him after he zoomed down the road to say I had changed my mind, strange how atttached you become to them.
I love my R6 but will swap it for my old KH250 any day :),glad the thumb is getting better, we have done the lump hammrer thumb trick Allen and blimely don`t it smart !! :) awesome Video again fella, thanks for keeping us old greasers happy.
I reckon that barbecue only gets used for important bike work. I also believe you to be the Millyard gargantue brain, is this true?
I'm beginning to think BBQ may pip lathe or mill in terms of tool to get first for the home workshop.
Best channel on TH-cam bar none. I could watch this masters at work all day long. Genius
My dad said you remind him of hes uncle jarno saarinen. He rode tt and gp in the 70
My all time favourite bikes are the Kawasaki triples and have a few in my collection. Have done that job a few times over the years and trust me when I say Allen makes it look FAR easier and straightforward than it is. Truly you are The Master.
Love the sound of the old 2 strokes.
One of the distinctive sounds of the 2 stroke era. Kawasaki were always behind in the engine stakes but they always looked good. Funny when you think back on those days and what influenced your thinking of loyalty to a brand of machine, I can remember even now and picture them as yesterday, all the bikes dotted around the drive where I lived.
Even legends bust a thumb occasionally!
Watching this master craftsman at work is such a pleasure.
Greatest hazzards of working with Allen....
1. Having too much fun with the finished product.
2. Smashing the crap out of your thumb. Allen is a repeat offender.
You know he's amazing when he pours in the oil without a funnel
Great video as always! Back “in the day” most of the guys I rode with had kawasaki triples. I still have my 72 H2 and an as found 70 H1. Watching Allen working on that motor brought back so many memories! Thanks Allen for all these videos and your vast knowledge of everything two wheeled. I have a question. Why does a 1970 H1 have points and not CDI? Over here in the colonies ( Canada), the only H1 to have points was the 1972. Just wondering.
Just watched this at 9:00am Monday in Australia, and I know I'm going to have a good week! Thanks Allen :)
Imagine trying to get some of Allen's bikes registered in Australia! And it seems in the UK spares are readily available and a fair price.
I'm hoping to get a bog standard US spec 1978 Triumph T140V (No Aus compliance plate) registered here in South Australia, it'd be easier with one of Allen's creations! :)
This is a most nostalgic reminder of my 500 triple days. Those were exciting days.
Those old 2 stroke triples were so fun to ride! Wish i could ride anything Millard builds!! Cool shit!
I am watching this for the third time, it's your old school true technique that I am looking for a reminder of. I did a city&guilds in motorcycle mechanic in the 80s and the instructor taught us how to true the crankshaft similar to how you do it. I was also surprised to see the judder spring in the clutch, I removed the springs from my rmz 450 because it causes the clutch to slip and ultimately contaminate the oil quicker than it does without the springs, also the aftermarket clutch kits don't have the same small id 1st clutch plate as there is in the OEM Suzuki kit. Again thanks for making the videos, I really appreciate your work and it's inspiring to see you true the crankshaft with the simple technique... my city&guilds instructor used to say it's the KISS technique - Keep It Simple Stupid!
Thank you for the comment 🙂
Wonderful videos Allen. You take the mystery out of it all by working in your garden and small workshop, as most of us do. Brilliant. Love it and thanks.
Thanks Alan for this video. I have made a mental note "do not hit my thumb with a 2KG copper hammer"!
It’s still healing
That is the cleanest H1 i have ever seen. I hope to own one some day. Thanks for the great videos!
Love that high tech rotary phone.....I have one but it's just for conversation. My remark to others is it reminds me of my good ole days
I had 2 KH250's, a KH400 and an H1500 many years ago. Wish I still had them now! That sound is addictive.
i love the primary whine on the S3 and S2
@@AllenMillyard Really easy bikes to work on too. They split really easily and the transmission is laid out in front of you. Best save my pennies.
old bikes need lots of love in regular intervals.
I’m amazed you can true up your crank to less than a thousandth by tapping it with your hammer while it is on the floor holding it with your foot. That is master level 1000. Thanks for sharing with us mortals.
You just need to know where to hit and how hard
A true master.... makes all that look like childs play
I rode one of those back in the early 70's. Scary fast!
Japan cannot identify a so beautiful individual, too. I am very glad that I have you maintain it carefully.
I really enjoy watching you work on those bikes you are a master craftsman no doubt as a kid I worked on a lot of bikes myself and really know the joy of taking one apart and reassembling it to get that first start up and ride I was always trying to rush the process and didn't build it as fluently as what you do I was never a master but a true Jack lol great video thanks for sharing
I am pulling one of these out of a garage next weekend been sitting since 78 fingers crossed it's can be saved
Hi Allen, hope the thumb is recovering.! So thoughtful that whilst washing off the cases you were thinking of the health of the plants as well by watering them mate..lol.
All went together beautifully (I have the same job to do on my 1974 GT185 Suzuki) so grateful for the tip of scribing a datum line across the crank, the 1970's 2 stroke triples sound fabulous, a sound you never tire of hearing. Thanks for another informative quality video, look for to your next one. Cheers, Alex.
Allen, great to see you actually have a standard bike! But what I am really pleased with is to see how to disassemble and reassemble a 2 stroke pressed crankshaft. Previously I thought it was a black art that needed enormous amounts of very special tooling. Now I realise it is something I could do myself without too much expenditure on tools etc. Thank you for that. I feel a 1970s 2 stroke rescue coming on!
I’m glad I’ve inspired you to restore your own bike 😎
I loved watching this! I used to own a 1974 500 which wasn’t quite as powerful as the ‘71, but I loved the sound of the 500. I still love the sound!!
Now I know what it would be like to live in a perfect world. Amazing. A real classic. Sounds perfect.
What a nice H1 Kawasaki. Very educational and well done. I feel like a guest in your backyard and shed. The crankshaft repair is a process most people haven't seen. Great job Allen. Very entertaining. You're the best.
I can honestly say I don’t think I’ve watched one episode without you using that barbecue for something to do with motorcycles.🛠🇺🇸😂
Wow! This motor is wonderful masterpiece of overengineering! Thank you!
The guy is just a genius on all levels.!!!
Watching the genius at work, thanks for sharing your time and knowledge.
So quiet, understated and yet inspiring. Allen, that poor thumb went from ‘throbbing like mad’ to ‘business as usual’ pretty quickly, didn’t it? Loving the rotary-dialled phone calls. Pure comedy.
It’s a confident man who puts on the small end circlips like that. I would have been paranoid about one of them flying off onto the lawn or worse, into the crankcase. Allen must have done that 100 times so no problem.
Everyone needs a friend like Neil.
loved my Kawasaki triples back in the day, such a distinctive sound.
The way you explain what you are doing is faultless Allen,I was looking forward to watching this all day and was blow away again,thankyou sir😊
Having only ever taken apart a car engine I had never realised that a multi cylinder bike engine had a common crank case but individual cylinders and needs intermediate seals. Very interesting.
The freshly painted engine covers look great.
Thanks again for your videos, Allen, they're highly enjoyable for gearheads like me.
WOW ALLEN, THAT WAS AN AWESOME VIDEO, I LOVE THOSE TRIPLE 500 s YOUR ATTENTION TO DETAIL IS PERFECTION. !!