40-Amp Upgrade question.

[WaynefromSCal]

Where would I find the Info/Directions for the 40-Amp Upgrade ??
Thanks to all...
Wayne Cornell

 

[wjbertrand]

Hi Wayne, There's a ton of information over on the ST-Riders.net site, including a for loan tool kit as well. Look in the archives of wisdom forum.

 

[John OoSTerhuis]

From the ST1100 AOW:

40 Amp Alternator Upgrade - A Two Part Series ! Now With VIDEO !! *

40 Amp Alternator Upgrade - A Two Part Series ! Now With VIDEO !! *

www.st-riders.net

Please note that one of the key parts for the upgrade, the base plate, is no longer available new stock from Honda. IOW, salvage/used only. There’s currently a salvage, complete alternator and alternator shaft assembly available for sale here on this site [edit:LINK].

John

 

[Oldbikefixr]

Per John's comments, the base plate is becoming scarce.
The videos and articles on the process are great.
The Clymer manual for the early ST1100 has a chapter with lots of photos. If you wish to do this, read and watch everything....twice. It's certainly doable, just time consuming.

 

[Ned in Utah]

Sold....I have an adaptor plate, used original 40 amp Honda alternator, and an alternator shaft with bearing I'd be willing to sell. I did my up grade on my '94 a couple of months ago with the help of John O's prior experience and all the others that have been done before. John put together a handy dandy install loaner kit that has all the instructions and tools and install equipment you would ever need to complete the upgrade. I got these extra parts when I thought the first one I found were not going to happen and sinced the plates are all but impossible to find, I picked them up just in case the first one didn't pan out, but it did, so I have these extra parts. Just been waiting for someone to decide to do the upgrade. $200 + shipping.

 

[Larry Fine]

PM sent.

 

[Larry Fine]

I have gotten a price estimate for adapter plate duplication: $450 for one or $350 each for ten.

Is that reasonable? Would there be a demand?

 

[John OoSTerhuis]

My opinion is that over time there could well be demand for 10 of the aluminum plates. However, I suspect that the other unique part necessary for the upgrade, the hardened steel splined shaft, will also soon (if not already be) no longer be available NOS; a far more expensive part to custom manufacture. Something to consider...

John

 

[Upt' North]

My opinion is that over time there could well be demand for 10 of the aluminum plates. However, I suspect that the other unique part necessary for the upgrade, the hardened steel splined shaft, will also soon (if not already be) no longer be available NOS; a far more expensive part to custom manufacture. Something to consider...

John

https://www.cmsnl.com/honda-st1100-paneuropean-1998-w-england_model4813/shaft-acg-damper_13411majg20/#.X5k1NminxTs

John, is this the shaft, if so it's still available at a good price from these. Although I don't think the plate is. The link isn't perfect, but scroll down and it's there.
Upt'North.

 

[Upt' North]

I have gotten a price estimate for adapter plate duplication: $450 for one or $350 each for ten.

Is that reasonable? Would there be a demand?

Larry, it might be worth reaching out to this geezer who seems to be all things for ST alternators.

https://www.ebay.co.uk/itm/Honda-ST1300-ST1100-Alternator-Pan-European-generator/254097991172?hash=item3b296ba604:g:oI0AAOSwM1JavIPT

 

[John OoSTerhuis]

John, is this the shaft[?]

Yes, that is the part: 13411-MAJ-G20
Unique to the ST1100. The upgrade bearing, bolts, and o-ring(s) parts can be outsourced, but the plate and shaft cannot... currently.

How many more shafts than plates were made by Honda for replacement stocks I don’t have a clue. I do know of a number of plates that were cracked by upgraders (using the mounting bolts to try to seat the assembled alternator shaft assembly when the inner split gear was not yet engaged in the flywheel splines!) and had to be reordered. IOW, more plates than shafts have been removed from stocks. FWIW

John

 

[rwthomas1]

Is the 28 amp alternator not rebuildable? I know they are considered marginal by some, but there are apparently people out there still running them and they are working correctly. If the 40amp unit is rebuildable, then the 28amp should be as well. Bearings, seals, winding copper, etc. are all commodity level items. There are two shops local to me that rebuild most any starter or alternator you could find. It might be much simpler to find a capable shop.....

RT

 

[ST1100Y]

Is the 28 amp alternator not rebuildable?

Hardly...
- stator freeze shrunk into casing
- everything sealed with Resin...

 

[rwthomas1]

Hardly...
- stator freeze shrunk into casing
- everything sealed with Resin...

Well, the next step is to take it to a shop and find the closest match to the configuration, then machine an adaptor, or case, or shaft to make it work. Granted, my view is a bit jaded as I have a machine shop, and machinist at my disposal, but this really isn't rocket science and would be hard pressed to sell a bike for this reason.

Larry's machinist's pricing is not realistic. $300 for that part, in a bulk order? A better solution is alternator from another source using the existing 28amp mount, etc.

RT

 

[John OoSTerhuis]

RT, have you looked the related threads here in the ST1100 Alternator sub-forum?:

ST1100-Alternator

www.st-owners.com

Also, over on ST-Riders.net? The AOW is public, register for the members forums, and search.

There are significant differences between the two charging system designs. Do you know what they actually look like? I really don’t see a stator from another model Honda being adaptable to the 28amper’s alternator shaft assembly. Then again, I could be wrong; but, I suspect that over all these years, that’s been looked at...

The 28 amp oil-cooled system was last used in ST1100s in 1995. In my 22 years on the forums I’ve yet to hear of a successful, reliable rebuild/repair shop of the stator. Anyone...? Bueller...?
25 years or more and still nobody’s reported a fix, and folks have indeed tried to find one.

Heres a thread that you and other folks might find interesting (stator repair/repotting):

I want to repair this alternator for an ST1100 and your're invited | ST1100-Alternator

My present alternator, with careful testing of it's output, shows one of the leads isn't producing volts. I was graciously given this alternator recently after my mention on the forum that I'd like to upgrade, since mine wasn't working at 25 years old and 75k miles. So, until a 40 amp...

www.st-owners.com

and another:

I have a couple 28A stators, that I overhauled. | ST1100-Alternator

I have soldered the field coil wire (white and black wire is connected to this wire) and stator wires to their perspective places. Re sealed with blue RTV, and leak checked. What I find interesting is I haven't been able to test for voltage. Ohms check out, between all of the connections, so...

www.st-owners.com

Anyone with a trashed stator, send it to RT. Maybe he can work the magic. Seriously, I’d be thrilled if we can keep more STs on the road!

FWIW

John

 

[ST11Nut]

I have a 28amp that I got from a fellow forum member that was reported to be working but the insulation on the external wiring was failing and the bike was upgraded to a 40 amp unit without trying to fix the 28 amp unit wiring.

If anyone wants it for shipping costs, let me know

 

[Larry Fine]

Granted, my view is a bit jaded as I have a machine shop, and machinist at my disposal, but this really isn't rocket science and would be hard pressed to sell a bike for this reason.

Larry's machinist's pricing is not realistic. $300 for that part, in a bulk order?

Would you be interested in pricing duplication? I can gather some pics, and send you a plate if necessary.

 

[rwthomas1]

Let me clarify: I run a maintenance dept, we have a full machine shop, and a machinist that works for me. Plenty of favors have been done for employees here, and work after hours, but its not like I can have multiple parts made for outside sources. That said, I'd be happy to take a look and see if there is a solution. Never seen a 28amp unit, or how it mounts. If someone wants to send me a dead one, great. I'll even pay the shipping since I'm curious.

RT

 

[John OoSTerhuis]

Never seen a 28amp unit,

Edit:


‘The stator is the part that fails, it‘s on the far right in my photo. Plenty of images of it in the links I provided above.

 

[rwthomas1]

‘The stator is the part that fails, it‘s on the far right in my photo. Plenty of images of it in the links I provided above.

Yes, I have looked at the posts. Repairing the 28amp appears possible if tedious. What I'd like to see is the mounting side of the 28amp compared to the 40amp adaptor plate and shaft. Could the 28amp unit be modified into an adaptor plate and shaft for the 40amp unit? There has to be commonality, they bolt into the same place on the engine. Or could the 28amp unit be modified into an adaptor plate to allow the installation of another type (non-Honda) alternator? Trying to think outside the box.

RT