40 amp upgrade...

I am hoping someone can help me with a parts list and any recommendations as to where to order parts from, I have seen lots of post but most I see as far as parts list are 3-4 years old and am not sure if part numbers would still be correct... Also can I get an estimate as to what price I am looking at for the parts to upgrade to the 40 amp???

Google is really awesome

http://koczarski.com/mmartin/Alt.htm

And just look at the honda sites, like cmsl for the parts

http://www.cmsnl.com/honda_model8286/

djowi said:

And just look at the honda sites, like cmsl for the parts

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He'll probably suffers an instant heart-attack once he sees the European prices there ;-)

More reasonable priced (except the usual suspects within the US):
https://www.davidsilverspares.com/

Parts list, tips and videos here:
http://www.st-riders.net/index.php?topic=942
Tool kit to do the deed:
http://www.st-riders.net/index.php?topic=545.0

Recent upgraders can chime in on best parts sources, but Ron Ayers, Service Honda and a couple others have been used by recent STOC loaner 40 amp alternator upgrade tool kit borrowers. Pricing just the 40 amp unit itself will give you a good idea of the current cheapest source for the whole list.

John

Check ebay and local mc scrap yards. You may be able to buy an entire used 96 or later engine with alt for less than price of new alt. Add some new o-rings and you're good as gold!

Here's the list.About $500.00
Call Keith at Mason City Honda.Tell him your an ST-Owners Forum member.You can copy/paste the list to him then follow up with a call to pay.We get an additional discount
masoncityhonda@gmail.com
641 422-0000
13411-MAJ-G20 SHAFT
* 11202-MAJ-G20 ALTERNATOR BASE
* 91004-MT3-003 BEARING (20x47x10.5)
* 31100-MAJ-G41 ALTERNATOR ASSY.
* 91302-MM4-003 O-RING (90x2.3)
* 32130-MAJ-G40 SUB-HARNESS, ALTNTR
* 95701-08070-00 BOLT, FLANGE (8X70) - quantity: 3
* 94001-06080-0S NUT, HEX, (6MM
38270-MAJ-G40, BOX ASSY., MAIN FUSE
* 38260-MAJ-G20, STAY B, FUSE BOX
* The fuseblock comes with two fuses:
o 98200-65500, FUSE G (55A)
* 93891-06016-08, SCREW-WASHER (6X16)
* 95701-06012-00, BOLT, FLANGE (6X12) - quantity: 2
* 90153-SB2-003, SCREW-WASHER (5X10) - quantity: 2
* 91358-MG9-003 O-RING (50.5X3.5)
* 91302-MA6-003 O-RING (61X2)
* 91356-MG9-003 O-RING (39.5X2.4)
* 40210-MT3-000 CAP, PROPELLER SHAFT
* 91361-MT3-003 O-RING (22.1X1.9)
* 91263-MT3-005 OIL SEAL (30X43X7)
Other than bearing 91066-HA7-672

That's a great piece of advice Pat, I should be on the lookout on Ebay to see if I can snag a nice used Engine with the 40 AMP alternator already in it.

I'm guessing the effort to replace the total engine < effort to replace the alternator alone..? Am I correct in assuming this?

Regards,
Vishnu

sirepair said:

Check ebay and local mc scrap yards. You may be able to buy an entire used 96 or later engine with alt for less than price of new alt. Add some new o-rings and you're good as gold!

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Vishnu. I had to replace a 40amp unit (with another 40). It can be done in an afternoon if everything comes apart ok. I read the articles on here and watched a couple of youtube videos. Hope that yours goes as well. Cheers

thepaleobiker said:

I'm guessing the effort to replace the total engine < effort to replace the alternator alone..? Am I correct in assuming this?

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Have wondered about this as well, as I have the used parts/engine to do either.

The 40 amp upgrade is a piece of cake compared to a major job like total engine R&R!

John OoSTerhuis said:

The 40 amp upgrade is a piece of cake compared to a major job like total engine R&R!

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+1... as you actually take the bike off the engine there...
(no kidding, I left the engine sitting on wooden blocks and lifted the frame off it... much easier then hoisting that 92kg/200lbs V-4 hulk around...)

Thank you for the kind words of encouragement! I still have not committed to the change, but I've a measly 28 AMP alternator so I'm always looking out to see what the elders in the community have to say about this topic. Pat made a great point about getting an entire engine for cheap, but others have also mentioned the Alt upgrade in itself isnt too bad - At this point, I am willing to spend $450-$500 to get it sorted out, maybe early next spring.

Cheers!

cammy moir said:

Vishnu. I had to replace a 40amp unit (with another 40). It can be done in an afternoon if everything comes apart ok. I read the articles on here and watched a couple of youtube videos. Hope that yours goes as well. Cheers

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Sorry if it appears that I implied changing the engine. What I meant was to buy the engine with alt, and pull the alt off to install on your bike. Bonus is that you basically have a free spare engine!

Pat, I think we got what you were saying, and were just commenting on why not swap engines, at least in my case. I'd be putting in an engine with 70k fewer miles and a good alternator. Just thinking out loud though!

It's definitely a legitimate question.
Does it make financial sense to spend $500+ on a 20 year old bike?And it does seem that they all go around the same mileage ,75K where other systems are in need or will be in need of servicing.
My '93 had about 83K when she started to go.I thought about it for a while,but she had too much sentimental value for me.(I picked it up on 9/11/01,flew to Boston from NYC and heard the news when I landed),Taken cross country and just loved how it performed for many years.
Just back on the road this week after 6 years laid up and it's like a new bike and continues to give me smiles,...

mznyc said:

It's definitely a legitimate question.
Does it make financial sense to spend $500+ on a 20 year old bike?And it does seem that they all go around the same mileage ,75K where other systems are in need or will be in need of servicing.
My '93 had about 83K when she started to go.I thought about it for a while,but she had too much sentimental value for me.(I picked it up on 9/11/01,flew to Boston from NYC and heard the news when I landed),Taken cross country and just loved how it performed for many years.
Just back on the road this week after 6 years laid up and it's like a new bike and continues to give me smiles,...

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I'll see if mine will break that mold as it's at 83245mi. Thinkin' properly taken care of electrical connections ought to extend that service of the alt. well into 100k.

DeanR said:

I'd be putting in an engine with 70k fewer miles and a good alternator.

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The big unknown is how the donated engine was treated and serviced in the past...
Continuously raced at the red-line or accumulating deposits while daily idling in commuting queues?
Coolant not replaced for a decade?
Missed a few oil changes?
Clubfooted shifter?
Tried burn-outs and wheelies?

A used engine from the bike of a rider I know well... maybe.
A used engine off unknown breed and usage... requires a serious inspection, thus tear-down and rebuild... endoscope, replacing w/pump, belt and pulleys, swapping gear box and clutch, etc...

ST1100Y said:

The big unknown is how the donated engine was treated and serviced in the past...

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It's mine Martin. '99 That's why I have entertained the idea.

DeanR said:

It's mine Martin.

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errr... and you still asking? Seriously? Trying to kid everyone here? :lol:
If you know the history of the donation engine that detailed it seems a no-brainer, doesn't it? ;-)

Still, engine swap is quite a task, not under 2, maybe even 3~4 days... proper tool-stock, platform, etc... 2nd person helping much helpful... and you'll need lots of space... the amount of parts flying around is going to be huge... BTDT, more then once...
But its an excellent opportunity to get really one with the bike... once every single bolt and small item has gone through your fingers, you are going to treat it differently :grin:

Swapping the alternator can be done flying solo, an easy days work...

ST1100Y said:

errr... and you still asking? Seriously? Trying to kid everyone here?

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No idea what you are saying here. I only mentioned it because Vishnu had brought up the possibility.