ST1100 Customizations

Last modified: Sat Apr 19 15:07:19 EDT 1997 
This page is from the www.xyz.com/st1100/ pages, with permission from the author Michael Galassi

WARNING!

Many of these changes will void your ST's warantee. Many of them require some mechanical adeptness. If you are at all hesitant about what you are about to do, go take a ride instead, it is MUCH safer.


From the ST1100 FAQ


Ron Major of Major Engineering has some excellent products designed especially for the ST1100. Some of the items include:

E-mail Ron at : ronmajor@pacificnet.net

Lights

All US ST1100's have non-standard Headlight bulbs. They are pricey if you buy them from your Honda dealer, but they will fit right in without any problems. The replacement H4 bulbs that you can get an any autoparts store won't fit correctly into the ST1100 headlight socket.

If you want to increase the wattage of your bulbs, or you just don't want to fork out the money to your Honda dealer, see the appropriate section below for the year of your bike.

 

'90 - '93
This is REALLY silly. Honda has a special bulb for the ST. Costs over $20 and is 45/45 watts. The ST is rated for a normal H-4 45/45 bulb. However, H4s won't fit snugly. Compare the stock bulb with the H4 and remove the excess fitting tabs on the H4 to match the ST bulb. Install. Voila! More watts, less cost. H4 bulbs are available at many places like K-Mart, Venture, Wal-Mart for $10 or less. (From Pan-Euro)

More specifically, the H4 bulbs have two very small tabs sticking out of the bottom of the metal bulb housing towards the bulb. These tabs have to be bent back in flat with the rest of the housing.

Also, there are 3 metal tabs that stick out from a normal H4 bulb. One straight up, the other two at angles pointing down. The two down pointing tabs need to be removed to fit properly in the ST1100 housing.

Once these tabs are removed and flattened, the bulb can be refit into the standard ST1100 headlight bulb socket and the clip replaced to hold it snug. The headlight will point straight and should not cause any problems.

'94 and up
Here are step by step instructions for getting an H4 bulb to fit properly in a '94 and up US ST1100 headlight housing. These steps remove the headlight assembly so if you don't want to do all of it, just start at Step 15 for a brief overview of the process.

Step by step instructions for 1994 or higher US-spec ST1100A. Based on inputs from Grant Norman, Rock Rhoades, Tom Vervaeke, and Steve Kelley. Important mistake not to make that I made: Many of the fasteners are interchangeable. Basically 2 sizes - all the screws and all the bolts. But they are different lengths, head types, and some bolts are countersunk. While I kept everything together in a tray, upon reversing the steps, I ended with countersunk bolts where plain bolts were necessary. Decided a quick trip to the HW store would be easier than disassembly. So keep the fasteners for each step in order and marked.

Tools and supplies needed:
Phillips Screwdriver
Hex tool from Honda toolkit (or equivalent)
10mm box or open-end wrench
10mm socket and ratchet (small drive OK)
Standard or Needle-nose Pliers
Standard coathanger
2 new H4 bulbs of preferred wattage
old burnt-out H4 bulb (optional, for practice)

Step 1 - remove the windscreen - 5 Phillips screws - also remove the nylon and rubber washers. They may not remain stuck to the screen if you don't pull them off now.

Step 2 - remove top instrument cover panel (the black piece with "HONDA" logo on it - 2 Phillips screws. The circular trim clip below the HONDA should remain in place with the panel.

Step 3 - remove the next instrument cover panel - 4 Phillips screws

Step 3A - remove the 2 Phillips screws from the inside panel (near and behind where the windscreen screws with the triangular holding plates mount).

Step 4 - Remove the 2 10mm bolts from the fairing cover (exposed when the instrument panel cover is removed in step 3).

Step 5 - Remove the one 10mm bolt and nut that hold the right and left fairing pieces together.

Step 6 - Just below the bottom leading edge of the headlight, remove the 2 Phillips screws holding the fairing cowl to the right and left fairing pieces (NOT the screws in the black triangular piece, which stay put).

Step 7 - Up on top, remove the 2 hex bolts and nuts that hold the top of the headlamp housing. Use 10mm wrench to hold the nuts.

Step 8 - Pop off both mirror/turn signal housings - let them swing free by the wires and safety cables. Remove both mirrors - 2 10mm bolts each. Remove bulbs from housings and set mirror/housing assemblies aside in a very safe place. Both mirrors must be removed to allow the right and left fairing pieces to have enough free play to release the headlight housing. The mirror bolts actually serve to secure the upper side fairing panels.

Step 9 - Remove the 4 Phillips screws and release the 2 clip buttons that hold the underside fairing shroud together. The clips release by inserting a flat blade screwdriver between the head and body and twisting apart (gently). The speedo cable runs through a slot in this fairing shroud. It is not necessary to remove the cable - just twist the piece over the front fender and let it hang out of the way. (NOTE - BE CAREFUL HERE - THE PLASTIC IS NOT RE-INFORCED AROUND THE HOLES IN THE RIGHT AND LEFT FAIRING PIECES.)

Step 10 - Remove the connectors from each of the 2 headlight bulbs. Mine were VERY tight!

Step 11 - Reach up from the underside and remove the 2 10mm bolts holding the bottom edge of the headlamp housing. These can be seen from the sides, and are best removed with a 10mm socket with short extension.

Step 12 - Lay 2-3 thick folded bath towels on top of the front fender, where the headlight housing will rest after you release it.

Step 13 - Remove of one small, #1 Phillips screw that holds a plastic clip that fastens the headlight adjusting cable to the top of the assembly. Carefully pull the headlamp assembly out. It has 2 rubber mounts over guide posts on the metal frame bracket. Once free of the guide posts, twist to the right and down to allow the adjusting cable to slip trhought the fairing pieces. Lay the assembly on the towels.

*** OPTIONAL Step 13a-b - if you want to pull the entire assembly out ***

Step 13a - Remove the one small Phillips screw on the headlight beam height adjustment knob. Remove the knob and spacing washer.

Step 13b - Remove the nylon hex nut from the headlight beam height adjustment stem. The adjustment cable will now be released so the entire headlamp assembly can be removed. **Note - on the non-ABS model, it may be necessary to remove one additional screw to release the cable mechanism.)

***** end optional steps ****

Step 14 - Remove the rubber dust boots. Mine were very tight around the bulbs, but went back on real easy!

Step 15 - Examine the spring clip assembly, Remove a bulb and compare it to the H4. The top tab on the H4 is narrower, the bottom tabs are in a different place, and one of the H4 tabs will hit the screw that holds the retaining clip in its pivot point. Note also that the forward pointing tangs (just under the bulb) on the STock are wider apart than those on the H4.

If you have an old burnt out H4 to play with, bend the tangs flat, bend the 2 lower tabs back, and insert - do not clip. Note that the H4 pivots freely from side to side, due to the absence of the two tabs. If you clip in place, the H4 will be forced to point sideways.

Step 16 - Cut a piece of stiff wire (from standard coathanger - not rubber coated (it will get HOT). Wire should be long enough to extend a half inch or so beyond either side of the H4 bulb housing, longer than the original tabs. On your new bulb (or test bulb, if you like) bend the H4 tabs back far enough to hold the wire firmly in place. Also flatten the forward pointing H4 tangs.

Step 17 - Insert the "wired" bulb in the socket and clip in place. Note that the clip presses down on one side of the wire quite tightly, but the bulb is flat in place and only great pressure can get it to bend from side to side.

Step 18 - Re-install boots. They won't go on real neatly around the clip area, as the clip will ride a bit higher due to the wire added. No big deal here.

Step 19 - Reverse steps 13 to 1 to re-assemble. Go slow and don't force anything. If plastic does not line up, get someone to hold it in place while you get fastener (screw or bolt) started. My right side fairing gave me fits, but I had removed many more fasteners than this in order to install the Fiamm air horns.

Optional Step 20 - While setup is fresh in your mind, remove and replace one of your new bulbs without taking anything off the bike except the connector and boot. You can see the bulb go in an out of the assembly through the headlight lens. Front wheel should be pointed toward whichever side you are working on.

Conservative estimate of total time for a mechanical novice to perform the above work: 2.5 hours tops. A good wrench could do it all in less than one hour.

Compiled by Steve Kelley - May 25, 1996

Suspension

Front Forks

Well, I spent Sunday afternoon (about 3 hours) changing the stock front springs to Progressive's. Turns out the task was not as difficult as I expected given some of the responses I received about the procedure. What I discovered is that it is relatively simple to change the springs(with the exception of that damn cartridge!) especially if you own a floor jack. I had great concerns of dropping the bike if the springs were removed, but found it quite easy to support with the adjustable floor jack. Contrary to some of the advice I received this job was done with the bike on the center stand for the entire procedure. The process is a one man operation (except for that cartridge!) FWIW here it is:

1. First support the weight of the front end by jacking up the engine (be sure to use a piece of wood between the jack and the bottom of the engine to avoid damage to the case).

2. Loosen the pinch bolts on the triple tee using an allen wrench, and remove the left fork cap. (It is under pressure, but will only come up about two inches if the weight is off the front wheel).

3. Remove the stock spacer, washer, and spring being careful to wipe the old fork oil off the components and not drip it all over the place. You do not need to keep the stock spacer. Instead, you need to cut a new shorter one from a piece of 1" schedule 40 PVC pipe. This new one needs to be exactly 3.25".

4. Now loosen the right fork cap. This cap will not come off like the left side because it is screwed onto the fork damper rod inside the fork. To expose the cap and locking nut below it, you need to lower the entire bike down onto the front suspension. Do this very slowly and you will see the right spring slowly rise out of the fork. You can go ahead and lower the bike till it bottoms out on the forks. Keep the floor jack in place to steady the bike!

5. To remove the right fork cap, simply unscrew it while holding the lock nut below with a 12mm wrench.

At this point it is advisable to consider designing a tool to help in the removal and replacement of the spring locking collar. I basically used a metal rod at least 12" long threaded on one end with the same metric threads as the fork damper. Screw an extra nut onto the end of this rod (half the depth of the nut) and tape it in place. Now screw the other half of the nut(with rod attached!) to the end of the fork damper rod.

Next, if you have a companion near by, push down on the spring (it may take two hands!) until the spring seat stopper is loose and have the other person remove the stopper. The washer, spacer, another washer, and the spring can now be lifted free. Discard the spacer and one washer as you will not need them again.

6. Next, drain the fork oil by loosening the nut at the bottom of the fork tube using a 10mm wrench. When it stops dripping, replace the nut and tighten. Be sure not to lose the small copper sealing washer!

7. Now add fresh fork oil (standard 7 wt. or I used 10 wt.). In order to measure the correct amount of oil to add to each fork, you must again create your own tool. Accurately measure a stick, rod , or whatever you have that can be inserted into the fork tube 5.5 " from one end. I suggest something long you can keep hold of so you don't accidently drop it into the fork tube! (5.5") is the distance from the top of the tube that the oil level should come up to. Pour some oil in and then place your measuring stick into the tube up to the pre-measured line. Pull it out, and if it is still dry, add some more oil(just a little at a time!). If you are careful and don't overfill, you can gradually raise the oil to the proper level. If you do happen to overfill, use something like an old turkey baster to remove the excess oil. Note: the left fork tube holds more oil than the right one.

8. Once the oil is in, you can insert the springs(tightly coiled side up as specified in the Progressive instructions)! This is contrary to the Honda maintenance manual instructions that say tight coils go down! If your homemade tool, still attached to the end of the fork damper, is long enough it should be sticking up just above the right fork spring.

9. Now for the hardest part! The spring will be sticking about two inches above the lock nut it needs to be locked under (after pulling the fork damper rod up as far as it will go). Be sure to put one of the flat washers on top of the spring. Now with a friend's help, one of you push down on the spring while the other pulls up on the rod. When the spring is compressed enough and the washer is below the locking nut, slide in the spring seat stopper. The locking nut is supposed to be 10.5mm(slightly less than a 1/2 inch) below the end of the fork damper rod to leave room for the fork cap to screw onto. (You might have to use a couple of pieces of scrap metal lodged between the coils of the spring to get enough grip to push the spring down)

10. Once the stopper is in place remove your homemade tool and screw the fork cap onto the right fork. Tighten the lock nut up against it. Now raise the bike till the front wheel is off the ground . Slowly screw the right fork cap into the fork tube being careful not to strip the threads.

11. The left fork tube can now be assembled. Be sure to put a flat washer on top of the fork spring, followed by the piece of PVC pipe you cut earlier. This side will require a little compression on the spring as you try to thread the fork cap into the tube. Go slowly and do not strip these threads either!

12. From here it is a simple matter of tightening the fork caps, and then the upper pinch bolts with the allen wrench. Remove the floor jack and GO RIDE!

Hal Rumenapp

Rear Shock

From: Phil Roberts, Peterborough England

I've always thought of the ST's rear suspension as a pretty good compromise between handling and ride, but had also thought that a little more control wouldn't go amiss. I think, in all honesty, that the OE Showa unit on my bike was past its best (somewhat prematurely, I might add) but nevertheless I was amazed at the improvement brought about by fitting a French-made Fournales air-shock in its place.

This unit is simplicity itself and really looks great, finished in chrome and blue-anodised aluminium. With no external spring, it's also a cinch to keep clean. Adjustment is limited to changing the air pressure (which is akin to changing the preload on a spring-type unit), with damping rates being pre-set at the factory. By using air as a spring, the unit is effectively rising rate in operation which means it's almost impossible to bottom out, and the Fournales units are unique in that they have an internally fitted relief spring which operates over the first portion of axle travel. This overcomes the traditional air-spring disadvantage of excessive initial spring rate and therefore improves ride comfort. The standard inflation pressure for the ST's unit is 15 bar (about 220 psi) which I've found needs no adjustment regardless of whether I'm riding solo or two-up with lots of luggage.

The improvements in handling are significant, with the occasional wallow in bumpy bends when loaded to the gunwales and riding "enthusiastically" completely eliminated. The bike maintains a much more even stance under firm acceleration, and is much more stable when ridden hard. Most significantly, these improvements are accompanied by a substantial improvement in ride comfort to which my wife, Jane, will happily testify.

The unit is fully rebuildable and, should you dislike the standard damping or spring rates, then these can be adjusted by the importers.

The Fournales range is imported and distributed in the UK by:

M.R. Holland (Distributors) Ltd.,
Unit 2,
Benner Road,
Wardentree Lane Industrial Estate,
Spalding,
Lincs. PE11 3UG

Tel: +44 1775 766455
Fax: +44 1775 710292

The unit for the ST1100 is expensive at a little over 400 stlg, but is of very high quality and comes with excellent backup service.

Lindemann Engineering can rebuild the ST1100 shock for considerably less than buying an aftermarket or OEM shock.
Contact them at (408) 371-6151

Tapered steering bearings

Handlebars

I know! This is what everybody wants to know about!) Heli-Modified (1-800-859-4642)

Mine have been replaced with V65 Sabre after market bars. I know of at least two other people who've replaced their ST bars with Sabre bars. Some people say its a pain and won't do it again, other say it was no big deal.

If you do replace your bars, your handlebar beauty cover has to go (unless you are REALLY creative). This is no big deal -- I've had many comments that the billet aluminum looks good. If you do decide to swap your bars you may need a "Bar Snake" to compensate for the missing bar end weights.} (From Pan-Euro)

Horns

Windsheilds

Rifle Windshields
(800)262-1237

Clearview Windshields
Heritage Square
18301 West Colfax R-3
Golden, Colorado 80401
Phone: 1-800-798-6089; 1-303-279-6086
If phoning from outside the USA the number (I think) is:
001-303-279-6086

Powerbronze Aerodynamics,
44 Brook Lane,
Ferring
Worthing
West Sussex BN12 5JD,
England.

Tel:- England 1-903-507-300 (from the States 011-44-1-903-507-300)
Fax:-England 1-903-507-683 (from the States 011-44-1-903-507-683)

As I mentioned they sell two versions extended by +3 inches (+75mm) or +5 inches (+125mm).

Seats

Corbin - Corbin Saddles makes two seats for the ST. Each has a backrest available (extra $$).
WWW - http://motorcycle.com/mo/mcads/mccorbin/
Phone - 800-538-7035; 408-633-3145; Fax: 408-633-3145

Sargent Cycle - Upholstery rebuilds seats to customer spec. I've met several people happy with their (fast) service. Jacksonville, Florida.
Phone - (800)-749-SEAT

Russell
PO Box 609-W
Fall River Mills CA 96028
1-800-432-9566

Diamond Custom Seats
902 Avenue R
Carter Lake IA 51510
712-347-5316

Travelcade
6325 Alondra Blvd
Paramount CA 90723-3750

Ventura Rack System

The Ventura rack system is a rear mounted rack that can extend the carrying capacity of the ST1100 (although it is not limited to only this bike).

Ventura Bike-Pack
H.S.I.
P. O. Box 336
Edmonds, WA 98020
800-688-6439

You can find a write-up of the Ventura system in the November, 1994 issue of Motorcyclist on page 85. The text of the article can also be found at the site mentioned in the next paragraph.

For pictures of a Ventura system on an ST1100, and for the Motorcyclist write-up, see the following WWW page: http://ernie.bgsu.edu/~norton/moto/ventura.html.

From: Michael Galassi nerd@xyz.com http://xyz.com/~nerd/

Well, I bit the bullet and bought the Ventura rack for my ST. Here are some comments, good and bad.

In time I'll probably purchase the matched bag and report on that, for now all I wanted is a place to strap on a couple of sleeping bags and a tent. All in all, I'm pleased with my $163 expenditure.

-michael

Radio/Cassette/CD

J&M Corp. is advertising a new "luggage mount" sound system for STs and other sport bikes. Call them at 1-800-358-0881 for a catalog and/or info. (From Pan-Euro)

CB/Intercoms

Autocom Pro Today on the net, I found the Autocom Pro System (http://www.bikenet.co.uk/html/autospec.html#nonoise) on BikeNet. Their online ad lists:

One of their testimonials (notice his choice of bike):

One high ranking Police Officer who tested the PRO system on a 1000 mile biking holiday using an ST1100 said: "it works superbly at any speed even with ear plugs, definitely far superior to any other intercom I have tried".

The most important feature for him is that being fully automatic it is hands free, making it clearly the safest system on the market.

One feature that realy catches my eye is the automatic volume control. Presumably, it senses increased road noise and automatically adjusts volume accordingly. Seems like a big plus to me--one not availalbe elsewhere to my knowledge.

Their system also seems to have been real-world tested: Autocom Pro System - The Ultimate Motorcycle Intercom As used by top racing teams for rider/pit communications, including James Whitham (Moto Cinelli Ducati) & Colin Edwards (Works Yamaha) in World Superbike, and Phase One Endurance and Team Beale Yamaha in the World Endurance Championship, as well as Addison Lee's London TaxiBike service.

From: Phil Roberts, e-mail: phil.roberts@molins.co.uk

Well, I'm that someone in ST-land who can share more info on this product...

My wife, Jane, and I have been using an Autocom PRO intercom system for over two years and can tell you, unreservedly, that it's the _beST_ intercom on the UK market bar none. Before buying the Autocom system we'd used a Sonic rider/passenger intercom (one of the best on the market before the Autocom came along) for about a year and it was a real revelation when we switched to the Autocom PRO.

The basic system consists of the intercom unit itself which is 9 volt battery powered and just larger than a pack of 20 cigarettes, and the headsets. The headsets are available in different styles to suit open-face, full-face and BMW "System" helmets. The earpieces are miniature, high quality, speakers foam-covered for comfort and are thin ( 8mm), but large enough to cover the average ear without causing pressure points. They attach to the helmet liner by way of a velcro backing. We wear Shoei X8 helmets which are very close fitting, and there's plenty of room for the earpieces. The noise-cancelling microphone is on a stiff boom which you bend to place just touching your lips. I chose to power the intercom from the bike via the optional power supply as battery consumption is quite heavy.

What's it work like, then? In one word, superbly, but you'd probably appreciate a bit more detail so here goes...

Due to the VOX system, the mic's are closed until someone speaks, so there's absolutely no amplified wind noise to batter your ears. The VOX is superbly fast and doesn't clip the first syllable like some inferior systems do - if someone says "instantly..." then that's exactly what you'll hear, not "stantly...".

Jon's basically right about how the auto-volume works: there's a sensor built into the lead which connects the rider's headset to the intercom unit which responds to increased wind noise around your head. So, the more ambient wind-noise, the louder the volume. What you wouldn't know is that the auto-volume system reduces the VOX sensitivity in line with the increase in ambient wind-noise too so that the mic's don't spuriously open. As you tend to speak louder as the ambient noise level around your ears increases the VOX still responds as soon as you speak. A very elegant solution which works at speeds of well over 150mph { on a track of course, officer ;-) }.

A 3.5mm stereo jack is provided so that you can play your Walkman, Discman or whatever through the intercom. There's a balance control so that you can bias the music input towards rider or passenger if you wish, and the intercom can be set so that speech overrides music or so that the music continues when you speak (useful if you like singing along to your favourite tunes...). If you already have a stereo system on the bike, Autocom can supply a switched lead which allows you to connect this to the intercom and listen either through the bike's existing speakers or the intercom.

Clarity of speech is first-class, and the music input gives as good as the source. The full duplex system allows you to have more coherent arguments with your passenger as you can shout at each other at the same time! Because the thing is fully automatic, it lends itself to being a fit-and-forget type product: mine's mounted in the tail of the ST, powered from an ignition switched supply via the optional power lead. This power lead also supplies 3 volts for a Walkman which we use extensively.

I know many people who've purchased other intercoms saying that they thought the Autocom was too expensive (as always, the best costs), but almost _always_ they end up binning their cheaper system and buying an Autocom PRO. I've lost count of the number of people I've recommended this system to, and it consistently comes out top in independent magazine tests. A large number of Pan-Clan (the UK ST1100 owners club) now use the system and, incidentally, much of the system's development work was carried out on an ST1100.

Hope this is of interest to others on the list.

Phil Roberts,
PanClan #029, STOC #059
Peterborough, England
e-mail: phil.roberts@molins.co.uk

Miscellaneous

Headlight cover

Bill's Plastic
2107 Sylvan Ave.
Dallas, TX
(214) 744-1170 (ask for Gary)


This page is from the www.xyz.com/st1100/ pages, with permission from the author Michael Galassi