40 Amp Upgrade Parts

[DaveM]

Does anyone know of all the exact parts that have to be ordered for a 40 Amp Upgrade?

I just want to make sure the dealer orders all the right parts....

Thanks!!

 

[sirepair]

Check Mike Martin's pages HERE.

And check with John OoSTerhuis about the traveling tool kit.

 

[BigTom]

What Pat said. I no longer have a parts list in my desk drawer...

 

[DaveM]

I just want to Thank You for the parts list. When I walked into Honda dealer to order parts they looked at me like I had three heads, never heard of 40 amp upgrade. Parts should be in 3-5 days, if all goes right hoping I will have bike back on road in time for NNESTOC. Thanks for all the input!!!

 

[DaveM]

Well, it took me about two and half hours today to disassemble my ST, I have everything off and waiting for the 40 Amp upgrade parts to come in tomm afternoon. I took a little longer to disassemble cause I labeled everything to make putting it back together go that much more smoother. I am not using the special toolkit and have removed the exhaust and dropped the oil pan and going to go in that way.

 

[ChrisK]

How did you get the Swing Arm off without the special socket? Did you just whack it ?

Hope your parts come in! (2.5 hrs doesn't sound bad at all!)

 

[DaveM]

How did you get the Swing Arm off without the special socket? Did you just whack it ?

Hope your parts come in! (2.5 hrs doesn't sound bad at all!)

Chris,

No, I did not whack it.....I used my own special tool, a small punch just the right size and tapped the lock bolt loose. Came off very easy!

Parts should be in tomm...hoping!! If not, Tuesday cause of holiday. Hoping to get it done for NNESTOC!

 

[DaveM]

Well, I completed the 40 Amp Upgrade over the weekend. The parts came in on friday afternoon and had it back together and running by Sunday night. Just about everything went smoothly, got a little frustrated with putting in the alternator drive gears. Could not get them in right away, tried for about 30 minutes, finally walked away, had lunch and came back and popped it in on the first try! Then installed the 40 amp with no problems getting it by the frame, that was a piece of cake!! Then came the fun job of assembling everything back together. I have to say, it went very smooth and thanks to JonB for the use of his motorcycle work stand and Laura for an extra pair of hands and assistance!! Put in the Honda OEM fuse block and had to move my accessory fuse block. Took the bike out sunday night and tested my new lights that I had installed and also rode on Monday. Bike runs AWESOME!!! Good to be back on the road and looking forward to adding some heated gear this winter! :bow1:

 

[sirepair]

IIRC mine had 96K on it when I did the upgrade (28 amper died!) Well worth it!

 

[DaveM]

That's great news!!! CONGRATULATIONS!!! Makes me think if I get a pre '96 1100 as my next bike I could do the upgrade myself.... I don't plan on upgrading my current, I have almost 90k on the bike. Would rather do it to a lower mileage scoot.

I met a guy last year at Moonshine and he had 221,000 miles on his '91 ST and still running strong!

 

[Jeff Hubbard]

I'm seriously considering making this one of my winter projects, along with some long-needed farkles. Glad it worked out well.

 

[George]

Ash, STick had over 150,000 when she got hers. If the engine is okay, all else is pretty easily maintained. Why not spend a few buck$ and keep her on the road for the second half.

All, don't know if this tip is in the instructions, but I marked the lock ring, pin, and frame so on reassembly I just lined up those marks, no torque wrench. It's worked so far.

Congrats, Dave, on completing a complex job on yur own. I've done three thru the oil pan but all three motors were out of the frame. Much easier that way.

 

[DaveM]

Thanks George....It wasn't as bad as I thought. The hardest part is having patience when something doesn't go right back in the first time. The bike has been running great, so far!!

 

[FrayAdjacent]

Posted this in a thread about ordering parts online, but thought it was a 40a alt thread:

A little bump for this one. I'm starting to look for parts for the 40a alt upgrade. I've got a couple items I'm selling that will finance this, but I want to get the best prices I can. I have checked out Beaver Dam for the parts, and came up with a total of $609.31, but then tried Service Honda and came up with $521.93.

Here's the parts list taken from the liST, with current prices from Service Honda:

qty1 13411-MAJ-G20 /SHAFT $35.77
qty1 11202-MAJ-G20 /ALTERNATOR BASE $36.41
qty1 91004-MT3-003 /BEARING $11.74
qty1 31100-MAJ-G41 /AC GENERATOR ASSY (ALTERNATOR) $413.48
qty1 91302-MM4-003 /O-RING $6.82
qty1 32130-MAJ-G40 /ALTERNATOR SUB-HARNESS $14.74
qty3 95701-08070-00 /FLANGE BOLT 8X70 $2.97 each


Removed the part for the pan gasket, even though I think I will drop the pan during the replacement, more for an inspection than anything.

I will also be getting a timing belt to replace while I'm in there, since my bike is at 80k miles right now.

I know I will need some 12ga wire as well, but I'll obtain that locally. Any other things I should need?

Once I get the parts on order, I'll see about getting the parts kit from John O. Then I'll plan on a 'maintenance day' (or two) at my house!

 

[FrayAdjacent]

Oh, I saw John O. post in the aforementioned thread that Service Honda had set up a kit for the upgrade and was charging $450 for it. Does anyone know if they are still doing that?

 

[DaveM]

Posted this in a thread about ordering parts online, but thought it was a 40a alt thread:

A little bump for this one. I'm starting to look for parts for the 40a alt upgrade. I've got a couple items I'm selling that will finance this, but I want to get the best prices I can. I have checked out Beaver Dam for the parts, and came up with a total of $609.31, but then tried Service Honda and came up with $521.93.

Here's the parts list taken from the liST, with current prices from Service Honda:

qty1 13411-MAJ-G20 /SHAFT $35.77
qty1 11202-MAJ-G20 /ALTERNATOR BASE $36.41
qty1 91004-MT3-003 /BEARING $11.74
qty1 31100-MAJ-G41 /AC GENERATOR ASSY (ALTERNATOR) $413.48
qty1 91302-MM4-003 /O-RING $6.82
qty1 32130-MAJ-G40 /ALTERNATOR SUB-HARNESS $14.74
qty3 95701-08070-00 /FLANGE BOLT 8X70 $2.97 each


Removed the part for the pan gasket, even though I think I will drop the pan during the replacement, more for an inspection than anything.

I will also be getting a timing belt to replace while I'm in there, since my bike is at 80k miles right now.

I know I will need some 12ga wire as well, but I'll obtain that locally. Any other things I should need?

Once I get the parts on order, I'll see about getting the parts kit from John O. Then I'll plan on a 'maintenance day' (or two) at my house!

94001-06080-0S NUT, HEX, (6MM) and don't forget about the fuse block.

 

[FrayAdjacent]

I always forget my nuts. Geeze.

 

[FrayAdjacent]

Looks like I'm gonna need that upgrade sooner than I had hoped...

I got a voltmeter installed just this week, and everything looked good. Got ~14.5v at anything above about 1800RPM. It would drop to about 12v at idle, but I expected that. Held up until I did about 250 miles today. Worked great out to the destination. On the way back after stopping at a light, the voltage didn't come back up from 12v for a while, then it would hover around 13v.

 

[DaveM]

Looks like I'm gonna need that upgrade sooner than I had hoped...

I got a voltmeter installed just this week, and everything looked good. Got ~14.5v at anything above about 1800RPM. It would drop to about 12v at idle, but I expected that. Held up until I did about 250 miles today. Worked great out to the destination. On the way back after stopping at a light, the voltage didn't come back up from 12v for a while, then it would hover around 13v.

Check the wiring for the voltmeter. Was it hot out? I found that my 28 amp would not put out alot when the temp was up around 85 degrees, it always read on the lower side. When it cooled down it was fine. I do have to say I feel alot better now that I did the upgrade. Still look at my meter, cause I am having flash backs from the 28 amp, but gettting use to the power the 40 amp kicks out!

 

[FrayAdjacent]

Well, I rode yesterday starting cold, and it still wouldn't go above 13V.

Just got an email back from Service Honda... the parts department apparently doesn't know anything about an upgrade kit.