ST_SHP
Parting a wrecked '91
I'm new here but have really enjoyed the forum thus far. A couple of days ago, I bought a well-used 1991 ST1100 that if I'm interpreting the VIN is correct is probably one of the first hundred ones made (the VIN is under 50). Mileage is at least 106K.
Anyhow, it's a beater. It's been wrecked and sat outside for an extended length of time. Since all the plastic was gone, I decided to rebuild it a little differently. I'm planning to make it a "UJM" (Universal Japanese Motorcycle) style of bike since my favorite bike has always been the 1981 Suzuki GS1000G shaft drive. I passed on a few other candidates in my journey. I nearly bought a 1981 Honda CB1000C but it was too much of a cruiser for my liking. The dual-range transmission and one year of production were neat, but also probably a parts nightmare. The other choice was a 1985 V65 Sabre. An interesting bike to read about, apparently many liked them and a few did not. This one didn't work out, and when an ST became available locally in my price range, I ended up with this one.
Here's a photo of it when I brought it home-
My plans are as follows:
1) Find out what works;
2) Find out what doesn't work (or is missing); and
3) Plan modifications and repairs/maintenance to make it roadworthy.
I performed an assessment the past couple of days, but it's been really cold here for Florida & I've not spent too much time in the shop. So far, I found the right turn signal, the tail light, and a couple of lights in the dash work. It's also not starting. It turns over but is not even trying to catch.
The horn, left side cover, and all front lights are missing. The front calipers were in a milk crate. The switches are spinning on the bars. The dash is broken- here it is after dissection:
Modifications
Gauges/dash
The first thing I looked at so far as a modification was an aftermarket dash. The Microdash comes from England and is pretty cool. I also liked the Koso dashes, but they were fairly small and didn't have all the features I wanted. One thing I found was that none of these dashes seemed to have an oil pressure readout. I didn't look at the high-end stuff that costs well over $1,000. One plan was to fabricate an aluminum panel and mount some digital gauges on it. After looking at the cost involved and not being sure I could adapt the cable drive to an electronic sender, I settled on using the stock dash and adding an oil pressure/temperature gauge from VEI Systems (I have this on my Concours and love it) along with a digital voltmeter and ambient temperature gauges. I'll probably source the latter two from Ebay. I'll also add a mount for my Archos 5 tablet. It functions as a 5" GPS navigation system and also plays stereo audio to my helmet via Bluetooth.
Handlebars
I'm replacing the handlebars with some UJM style ones I found on Ebay. Depending on how they fit/feel, I'll probably shim up the mounts by using the extra top mount/longer bolt trick. I'm buying new switches for both ends as the stuff on it was extremely crusty & the stuff on Ebay didn't look much better.
Fairing
I'm planning to add a Vetter Windjammer. I found I was not the first one to do so- another member here has done it with good results. I have one on my GS and it is great for riding. The one on my Concours just doesn't give the same coverage, even with a 7" taller windshield. My prelim viewing shows two bolts per side that may be able to be used with some angle to mount the Vetter.
Luggage
I got two bags with the ST, but it turns out they are really rough. I'm more of a tail trunk fan anyway, so my plans are to fab up an aluminum plate on the rear and add a large trunk.
Electrical & lighting
I'm working on how to add a projector headlamp to a 7" headlight so I can run HID properly. I have the HID ballasts & bulbs in my other bikes, but the pattern is not as tight as it should be. After some research, I found a projector is the best way to achieve this. On the other two, I added sub-panels for power in the fairings, and I'll do the same here. I also add a connector to the battery for a battery maintainer. I'm replacing the dash bulbs with #158 LED bulbs from the Superbright LED place. I used these in my GS rebuild, and like them. Ditto the tail 1157 bulbs and 1156 (formerly 1073) turn signal bulbs.
Repairs & maintenance
As for repairs and maintenance, here's what's on the radar after my inspection today:
1) Rebuild carbs, replace fuel filter, flush & coat tank. Looks like there was a small fire in the air cleaner at one time. The rear rubber boot is crispy and the mounting point for the base is melted (cosmetic only, still attaches OK) as is the vertical piece inside the lid.
2) Replace spark plugs.
3) Rebuild all calipers & master cylinders plus clutch hydraulics, and replace all hoses. Will make longer brake/clutch hoses as needed from braided hose & banjo fittings. Rear rotor is trashed, so I'll get a new one for there. The fronts may be usable. Front wheel to be repainted.
4) Replace wheel bearings & seals & reseal the forks. Probably do the head bearings as well.
5) Replace both tires.
6) Flush cooling system & (modification) install a 180~185 degree thermostat with appropriate fan switch. I tested the t-stat that was in the bike today in a pan of water with a meat thermometer and it didn't open until about 200 degrees. There were no markings on it to indicate a temp. The fan switch was marked 100-on, and I tested it in the pan with a multi-meter and it didn't close until right at 210 degrees (100 c is 212 f). In my mechanical ventures, I have learned a lot about cooling systems, which has been necessitated by our very hot & humid weather here in Florida. I want to be sure the cooling system is up to snuff. The hoses on the cooling system do not look to be too old, so they will stay.
7) Replace damaged right valve cover (used part, new gasket). Adjust valves while I'm there.
8) Sandblast exhaust pipes and coat with a Techline coating. I've used their Turbo-X coating on some car projects and it is good stuff. Will probably change out the mufflers, since they do not appear to be very substantial and I don't like the style.
9) Add crash bars.
10) Patch & repaint existing plastic pieces. The front fender has a small hole in it, and the tank cover has a couple of abrasions. One side cover was missing and the tail cover cracked, so whatever I end up with there will be repainted. I'll more than likely keep it gloss black.
11) Clean, clean, and clean! It is filthy from sitting outside. At least in my shop it is out of the elements.
I'm favorably impressed with how easy this bike is to work on. Plus I found the spin-on oil filter is the same one my Concours uses via the adapter I put on it. I know not having all the plastic is a big difference, but it's cool having the plugs & valve covers right there.
I'll update here periodically as I make progress. I'm still sorting out what needs to be fixed and what needs to be replaced and souring parts.
Anyhow, it's a beater. It's been wrecked and sat outside for an extended length of time. Since all the plastic was gone, I decided to rebuild it a little differently. I'm planning to make it a "UJM" (Universal Japanese Motorcycle) style of bike since my favorite bike has always been the 1981 Suzuki GS1000G shaft drive. I passed on a few other candidates in my journey. I nearly bought a 1981 Honda CB1000C but it was too much of a cruiser for my liking. The dual-range transmission and one year of production were neat, but also probably a parts nightmare. The other choice was a 1985 V65 Sabre. An interesting bike to read about, apparently many liked them and a few did not. This one didn't work out, and when an ST became available locally in my price range, I ended up with this one.
Here's a photo of it when I brought it home-
My plans are as follows:
1) Find out what works;
2) Find out what doesn't work (or is missing); and
3) Plan modifications and repairs/maintenance to make it roadworthy.
I performed an assessment the past couple of days, but it's been really cold here for Florida & I've not spent too much time in the shop. So far, I found the right turn signal, the tail light, and a couple of lights in the dash work. It's also not starting. It turns over but is not even trying to catch.
The horn, left side cover, and all front lights are missing. The front calipers were in a milk crate. The switches are spinning on the bars. The dash is broken- here it is after dissection:
Modifications
Gauges/dash
The first thing I looked at so far as a modification was an aftermarket dash. The Microdash comes from England and is pretty cool. I also liked the Koso dashes, but they were fairly small and didn't have all the features I wanted. One thing I found was that none of these dashes seemed to have an oil pressure readout. I didn't look at the high-end stuff that costs well over $1,000. One plan was to fabricate an aluminum panel and mount some digital gauges on it. After looking at the cost involved and not being sure I could adapt the cable drive to an electronic sender, I settled on using the stock dash and adding an oil pressure/temperature gauge from VEI Systems (I have this on my Concours and love it) along with a digital voltmeter and ambient temperature gauges. I'll probably source the latter two from Ebay. I'll also add a mount for my Archos 5 tablet. It functions as a 5" GPS navigation system and also plays stereo audio to my helmet via Bluetooth.
Handlebars
I'm replacing the handlebars with some UJM style ones I found on Ebay. Depending on how they fit/feel, I'll probably shim up the mounts by using the extra top mount/longer bolt trick. I'm buying new switches for both ends as the stuff on it was extremely crusty & the stuff on Ebay didn't look much better.
Fairing
I'm planning to add a Vetter Windjammer. I found I was not the first one to do so- another member here has done it with good results. I have one on my GS and it is great for riding. The one on my Concours just doesn't give the same coverage, even with a 7" taller windshield. My prelim viewing shows two bolts per side that may be able to be used with some angle to mount the Vetter.
Luggage
I got two bags with the ST, but it turns out they are really rough. I'm more of a tail trunk fan anyway, so my plans are to fab up an aluminum plate on the rear and add a large trunk.
Electrical & lighting
I'm working on how to add a projector headlamp to a 7" headlight so I can run HID properly. I have the HID ballasts & bulbs in my other bikes, but the pattern is not as tight as it should be. After some research, I found a projector is the best way to achieve this. On the other two, I added sub-panels for power in the fairings, and I'll do the same here. I also add a connector to the battery for a battery maintainer. I'm replacing the dash bulbs with #158 LED bulbs from the Superbright LED place. I used these in my GS rebuild, and like them. Ditto the tail 1157 bulbs and 1156 (formerly 1073) turn signal bulbs.
Repairs & maintenance
As for repairs and maintenance, here's what's on the radar after my inspection today:
1) Rebuild carbs, replace fuel filter, flush & coat tank. Looks like there was a small fire in the air cleaner at one time. The rear rubber boot is crispy and the mounting point for the base is melted (cosmetic only, still attaches OK) as is the vertical piece inside the lid.
2) Replace spark plugs.
3) Rebuild all calipers & master cylinders plus clutch hydraulics, and replace all hoses. Will make longer brake/clutch hoses as needed from braided hose & banjo fittings. Rear rotor is trashed, so I'll get a new one for there. The fronts may be usable. Front wheel to be repainted.
4) Replace wheel bearings & seals & reseal the forks. Probably do the head bearings as well.
5) Replace both tires.
6) Flush cooling system & (modification) install a 180~185 degree thermostat with appropriate fan switch. I tested the t-stat that was in the bike today in a pan of water with a meat thermometer and it didn't open until about 200 degrees. There were no markings on it to indicate a temp. The fan switch was marked 100-on, and I tested it in the pan with a multi-meter and it didn't close until right at 210 degrees (100 c is 212 f). In my mechanical ventures, I have learned a lot about cooling systems, which has been necessitated by our very hot & humid weather here in Florida. I want to be sure the cooling system is up to snuff. The hoses on the cooling system do not look to be too old, so they will stay.
7) Replace damaged right valve cover (used part, new gasket). Adjust valves while I'm there.
8) Sandblast exhaust pipes and coat with a Techline coating. I've used their Turbo-X coating on some car projects and it is good stuff. Will probably change out the mufflers, since they do not appear to be very substantial and I don't like the style.
9) Add crash bars.
10) Patch & repaint existing plastic pieces. The front fender has a small hole in it, and the tank cover has a couple of abrasions. One side cover was missing and the tail cover cracked, so whatever I end up with there will be repainted. I'll more than likely keep it gloss black.
11) Clean, clean, and clean! It is filthy from sitting outside. At least in my shop it is out of the elements.
I'm favorably impressed with how easy this bike is to work on. Plus I found the spin-on oil filter is the same one my Concours uses via the adapter I put on it. I know not having all the plastic is a big difference, but it's cool having the plugs & valve covers right there.
I'll update here periodically as I make progress. I'm still sorting out what needs to be fixed and what needs to be replaced and souring parts.
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