Kawasaki Z1 900 engine rebuild - Episode 5 

Wow that's a bit of a jigsaw

@@stephencroft6481 His wife is watching Strictly and The Voice, and he probably can't tolerate it (nor should he)

Same scene just played out in my house , Simon. Millyard brings blessed relief once again.

And I thought you were going to put your engine in the dishwasher, my wife was a bit upset when I did that

And there's no match of the day to look forward to neither !!!

I’ve thought to take pictures as I go with stuff a *lot* less complex, then bag parts up with labels…

Allen's a whiz for sure. But always remember that video producers only leave in the completed product what they want us to see. Mistakes and bloopers are edited out or re-shot.

It's fair to say that Mikuni carbs on early Kawasakis are incredibly well designed. Wherever possible they used the same screws across the board, or made sure that fasteners were easily identifiable. As long as you know which holes need bolts, which need screws and which have something a bit special (which probably won't fit anywhere else anyway), it's hard to go wrong. But I must admit I've done a slight modification and swapped the Plasticine-headed JIS screws for Allen Bolts. It upsets the purists but works better from a practical perspective, and it's right for the period (I first fitted Allen Bolts to my Z650 carbs back in 1980-saomething.....)

Start with a carb that doesn't matter. (One from a junk engine headed for the scrap yard). Once you get familiar with them at a personal level, they aren't so mysterious. Just like anything else you are familiar with. Get your hands on and explore! 😀🙂

absolutly fine till reassebly, and the fact im 50 and couldnt remember what i did yesterday.

Takes time actually 😂😂 I rekt my carb 3 times just to reinstall it again until i got it right😂😂

As engineer types we are always aware of where parts are & what part goes where & we are also aware if you believe that you'll believe anything 😏😁👍.

@@bish1121 🤣🤣🤣I struggle with 100 piece jigsaws so you can imagine what I'd do with a set of carbs like these.

They certainly are wrong

Yes I learnt this from Allen sometime ago when he was making a appearance on one of Henry Coles programs. 😊

they must have a screw loose

@@stevec-b6214 🤣🤣🤣

The Bob Ross of engineering.

Me too. HIs videos seem to force me to pay attention and relax.

Exactly the same here. 👍

I hear ya man 👍

They could do it with eyes closed

WYPO torch tip cleaning kit…

Of course from modern perspective they look complicated when we have all the complexity inside the silicon chip. As mechanical engineer I cannot help thinking what an absolutely thankless task it has been to design a carburettor that works somewhat ok for low, medium and high revs and that supplies the engine with enough fuel during acceleration all the while having manufacturing, assembly, longevity and maintenance in mind. So it jars me when someone dismisses that as ""complicated". Maybe in the sense that injection seems to be less complicated (though I've never taken a mechanical injection apart) but given the task to supplying an engine with a carburetor I don't think it is unnecessarily complicated. But every part and feature is there for a reason and every design has a history.

Doesn't matter, but where possible I do the same. They do have the size of the main jets on the jets themselves, so easy to put the larger ones in the middle carbs even if all put together for cleaning.

PS Perhaps that should be the next project. (1100 barrels with an ultra-long stroke.)

i told the wife i got one to clean her jewellry

Its spot on to take the time to get a good fitting bit, but as Alan says, Japanese bikes use JIS, which is different again to Philips, pozi and supadrive.

​@@gs425Yes. You are quite correct. JIS is different. Trinidad & Tobago.

@@gs425 I wonder why the Japanese manufacturers didn'tput out the message back in the 1970's that you needed JIS screwdrivers for Japanese motorcycles and cars, but let the stubborn rumour take form that the Japane screws were made from cheese. I don't think even proper mechanics were aware of it back then. It should have rung a bell for me, though, when the "joke" screwdrivers from the Honda toolset pitted perfectly to the tiny screws on the master cylinder lid, whereas the expensive Bahco didn't.

@erik_dk842 or was it because no one bothered to read the official workshop manuals. Most professional mechanics I meet nowadays don't fully understand the difference between Philips and pozi even nowadays for instance , and insist on jamming a snap on Philips into everything!!!

@@gs425 LOL And if you point it out, their answer is: JIS, WhAt ArE YoU TaLkInG AbOuT? JuSt UsE A QuAlItY ScReWdRiVeR. (And a hammer to force the poor screw head into shape)

Good point well spotted I do usually have the lid on when it’s running 🙈

@@AllenMillyard ok bud, just making sure you stay well,also, Henry's got some chair upholstery for you to do ,if your interested?

I tried to throw out a pair of bow-legged side cutters, but my dad picked it out of the trash and put it back. Then I welded the jaws together..

Ok will do in next video 🙂

@@AllenMillyard Excellent, cheers!!!

like me, i can play anything on piano, just that the notes are not always in the right order

dont forget 'it fits just perfectly' as well, theyre his catphrases, should make a tshirt with them on :)

The Japanese didn't do anything to make it known that JIS screw heads are not just poorly made Phillips heads