Mark Hosier's 40 Amp. Alternator Installation Procedure

PREFACE -

I recently completed the 40-amp upgrade on my 1994 ST 1100A. Thanks to Mike Martin's excellent web site with his write-up on the upgrade and to John Oosterhuis's special tools and invaluable advice, the upgrade went smoothly. Because of my background in test engineering, I decided to write a high-level disassembly and reassembly procedure before I started the upgrade project.

The procedure is high level, e.g., I say, "remove gas tank," but don't describe how to remove the gas tank. I do provide a reference for where to get the actual procedure for removing the gas tank. For the common steps in my procedure, I reference both the Honda Service Manual, and the Haynes Service Manual. For the 40-amp buildup and installation steps, I reference Mike Martin's tips (with John Oosterhuis's additional comments). I also reference Mark Frost's swingarm tips when reassembling the swingarm and pumpkin.

Again, this is a high-level procedure, but it provides references in each step, and it provides a logical disassembly and reassembly process.

- Numbers in brackets [ ] refer to the Honda Service Manual (91-94).

- Numbers in parentheses ( ) refer to the Haynes Service Manual.

- {MM #nn} refers to Mike Martin's tips (with John Oosterhuis' comments) here.

- I recommend contacting John Oosterhuis before doing the upgrade. John has personally been in on many upgrades and has provided technical and moral support via phone on scores of upgrades including mine. He also has all the special tools required for the upgrade. He will gladly mail them to you if you reimburse for the postage.

- I also recommend that you have both the Honda Service Manual and the Haynes Service Manual available before you begin the upgrade. The Honda Service Manual provides excellent exploded parts drawings and the Haynes Service Manual gives step-by-step procedures and provides actual photographs.

Mark Hosier, STOC #119

DISASSEMBLY -

1.   General:
   • Clean wheel, swingarm, and underside of bike thoroughly before disassembly
2. Remove plastic:
   • Remove bags [2-2]
   • Remove seat [2-2]
   • Remove side covers [2-2]
   • Remove pivot covers [2-5]
   • Remove top shelter [2-5]
   • Remove lower fairing [2-4]
   • Remove rear fender extension [2-4]
3. Remove gas tank [2-11], (4-3)
   
   • (Remove before removing final gear case because it's easier to access the 4 nuts.)
4. Drain engine oil
5. Drain final gear case (1-19) MM Note: This isn't necessary if you keep the unit upright when you remove it.
6. Remove rear wheel [14-2], (7-20)
7. Remove final gear case (pumpkin) [12-3], (6-19)
8. Remove swingarm [14-8], (6-17)
9. Remove bolt holding gear shift pedal and tube holder [17-8], (6-3) MM Note: I didn't do this.
10. Bend brake line holding tab up 45º {MM #11}
11. Remove two bolts from gearshift linkage cover {MM #11}
12. Cut charcoal canister hoses routing bracket off of bottom frame crossmember so the new alternator can fit through frame members (some STs don't have the bracket, mine did)
13. Remove alternator:
    • Disconnect negative battery cable at battery, positive battery cable at starter relay [17-7]
    • Disconnect 2P and 3P connectors from alternator [17-6]
    • Disconnect voltage regulator 6P connector [17-5]
    • Remove voltage regulator
      • (A new voltage regulator is part of the 40-amp alternator)
    • Modify bike's wiring harness {MM #16}
    • Remove stator coil [17-8], (9-23), {MM #1}
    • Remove alternator shaft assembly [17-9], (9-23)

REASSEMBLY -

1.   Assemble new alternator {MM #2-8}:
   • Remove parts from old alternator drive assembly
   • Assemble new alternator drive assembly
2. Install new alternator drive assembly {MM #9-10}
3. Install new alternator {MM #11-12}
4. Trim & install alternator cover {MM #13}
5. Install 2 bolts on gearshift cover
6. Install gear shift and tube holder with bolt [17-8], (6-3)
7. Install extensions & route hoses correctly {MM #14}
8. Install new alternator wiring harness to alternator and route. Ring terminal at alternator output is pinched between two 6mm nuts.
9. Connect 2P connector to wire from alternator
10. Install main fuse block (a good place to install this is where the removed voltage regulator was installed){MM #15}
11. Connect alternator output to fuse block
12. Connect positive battery cable and new 10 gauge wire to starter relay
13. Connect other end of 10 gauge wire to fuse block
14. Connect cable to negative battery post [17-7]
15. Install engine oil drain plug and fill engine sump
16. Start engine and measure voltage at battery. It should read >14 volts {MM #17}
17. Install swing arm [14-8], (6-18)
18. Install final gear case (pumpkin) [12-3], (6-20)
19. Hand tighten pumpkin/drive hub flange nuts
    • {See "Additional 40-amp Upgrade Tips - Swingarm Tips"}
20. Fill final gear case
21. Install rear wheel [14-2], (7-20)
    • {See "Additional 40-amp Upgrade Tips - Swingarm Tips"}
22. Torque pumpkin/drive hub flange nuts
23. Install gas tank [2-11], (4-3)
24. Secure wiring with wire ties
25. Reinstall plastic [2-2 through 2-5]

If you successfully completed the above steps, congratulations! Your ST is no longer amperage challenged.

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Last updated on January 26, 2014     © 2002-2014 M. E. Martin, all rights reserved.