Kawasaki S1 Four Cylinder Bike - How Its Made

[Triple Parts]

EPISODE 1 - CRANKCASES

https://www.dropbox.com/s/d4k1ecz042w2g ... S.mp4?dl=0

In this video I show how I converted a pair of Kawasaki S1 250 crankcases from 3 cylinder to four cylinder and fitted Kawasaki S3 400 barrels making the engine around 550cc with +0.5mm pistons.
The process is carried out in my home workshop and shed using mainly hand tools and a 1950's vintage milling machine and my TIG welder which is a 15 year old 240V, 200A, DC/AC machine, and I use 5% silicone filler wire for welding cast aluminium.
Hope you enjoy the video

Best Regards
Allen Millyard

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[Triple Parts]

EPISODE 2 - CRANKSHAFT ASSEMBLY

https://www.dropbox.com/s/tl8hfn8h8bpah ... Y.mp4?dl=0

In this video I show you how I made a four cylinder pressed up crankshaft with a 90 degree 1 - 4 - 2 - 3 firing interval.
This crankshaft is for my 550cc four cylinder engine that is based on the Kawasaki S1 250 triple engine.
Hope you enjoy the video

regards
Allen Millyard

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[Triple Parts]

EPISODE 3 - GEARBOX OUTPUT SHAFT

https://www.dropbox.com/s/i0lmxqgf0ger5 ... T.mp4?dl=0

In this video I am making the gearbox output shaft out rigger support bearing and extended sprocket for my four cylinder Kawasaki S1 550cc engine.
This modification allows the engine to be re positioned centrally in the frame and for the chain to line up with the front and rear sprocket.
Hope you enjoy the video

best regards
Allen Millyard

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[Triple Parts]

EPISODE 4 - GEAR CHANGE SHAFT & SPROCKET COVER

https://www.dropbox.com/s/md9h0hfpssmkw ... R.mp4?dl=0

In this video I show how I extend the gear change shaft and sprocket cover for my Kawasaki S1 Four Cylinder engine.
When I was rummaging for the parts to assemble the bottom end for the next episode I realised that I hadn't modified the gear change lever so this is an extra episode .
Best regards
Allen Millyard

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[Triple Parts]

EPISODE 5 - BOTTOM END BUILD

https://www.dropbox.com/s/3f3232s7o4kw2 ... D.mp4?dl=0

In this video I will be putting together the bottom end of my Kawasaki S1 550cc four cylinder two stroke engine.
Hope you enjoy the Video
Best regards
Allen Millyard

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[Triple Parts]

EPISODE 6 - TOP END BUILD & CYLINDER REBORE

https://www.dropbox.com/s/xpcw7zsfx4gix ... E.mp4?dl=0

In this video I'm putting together the top end of my Kawasaki S1 550cc four cylinder engine and showing how I re-bore the cylinders using my mini bore cylinder boring machine to fit over size pistons.

regards
Allen Millyard

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[Triple Parts]

EPISODE 7 - FIRST START, IGNITION TIMING & CARBS

https://www.dropbox.com/s/5xlt7l4twz27j ... S.mp4?dl=0

In this video I'm finishing off my 1974 Kawasaki S1 550cc four cylinder engine build making the stator plate to fit 4 sets of contact breaker points and setting the ignition timing. Stripping, cleaning, repairing and fitting the carbs then fitting a set of Delkevic H2C chrome header pipes. I then take it to my friend Henry Cole's farm in the Cotswolds where there is no issues with making a bit of noise. It was a bit loud at times, but the engine started pretty easily and runs really well considering its on open carbs and headers. I will be fitting it into bike in the near future and will post a few videos as it progresses.

Thank you for watching, I hope you enjoy it.

regards
Allen Millyard
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[Triple Parts]

EPISODE 8 - FRAME REPAIRS

https://www.dropbox.com/s/p9w2bkobjaal1 ... S.mp4?dl=0

In this video I find an old frame for my Kawasaki S1 550 four cylinder engine, it has seen better days but is repairable. It is a bit rusty in places because it's from a UK bike and has seen many salty winter rides in its life time and the original Kawasaki frame paint didn't seem to last well. It's been stored outside for a few years but with a little effort it will be restored to better than original condition with a coat of 2 pack epoxy gloss black paint finish.

The four cylinder engine fits into the stock frame with new mounting bolts and a few new spacers. I used 1mm thick slitting wheels and 120 grit flapper wheels on my angle grinder to repair sections of the frame.

I'm sorry if I sound a bit different at times I was suffering a bit with a cold ash the time, but am better now. Hope you enjoy the video,

regards
Allen Millyard
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[Triple Parts]

EPISODE 9 - FRAME ASSEMBLY

https://www.dropbox.com/s/m517ectc6mv94 ... Y.mp4?dl=0

In this episode the frame is back from being painted and bright zinc parts are re-plated so I can start the assembly of the frame and then fit the four cylinder engine, making up spacers and making special bolts as I go.

regards
Allen Millyard
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[Triple Parts]

EPISODE 10 - FRONT BRAKE

https://www.youtube.com/watch?v=56d_fIfreGo

I am making a Kawasaki S1 550 four mainly from spare parts that I have collected for many years and amongst the parts was a Kawasaki Z900 A4 front disc. The z900 disk is bigger in diameter than the standard KH250 disc so will be a good upgrade for the 550 four, the central mounting bore and bolt holes centres are the same so it will fit straight onto the KH250 hub. Because the disk is larger in diameter the calliper mounts are too low on the KH250 forks. In this video I show how I made the calliper fit with a bit help from Charlie Weaver supervising as usual.

regards
Allen Millyard
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[Triple Parts]

EPISODE 11 - FINAL EPISODE

https://www.dropbox.com/s/kmp4162zs1hp5 ... E.mp4?dl=0

This is the final episode in the series. The bike is finished and running well and I've covered 200 miles so far running in the engine.
Hope you enjoyed the series although it doesn't cover every aspect of the build it gives a flavour of how I make my bikes.

regards
Allen Millyard
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[Triple Parts]

EPISODE 12 - TWIN DISC CONVERSION

https://www.dropbox.com/s/wr7qdmpvt81l6 ... N.mp4?dl=0

This video shows how I upgraded the front brake of my Kawasaki S1 550 four cylinder from its original single disc to twin disc retaining a factory look.

The S Series Kawasaki triples did not have calliper mounting lugs on the left hand fork like the H Series bikes so I convert the left hand fork slider to fit on the right with the calliper mounts pointing forward and repositioned mudguard mounting lugs.

regards
Allen Millyard
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