From A to … ST

Joined
Dec 27, 2004
Messages
14
Location
Chicago
Hello good people of the Forum. It’s been a while, since I visited you regularly.
I started to write this story, but erased it as it might be too boring. The point is, my 1991 ST sat in a storage , untouched, since 2009 . I kept thinking about bringing it back to life every spring, but life went its own way. Finały this past winter, I packed the bike and shipped it to Poland, where I was to spend several months. Also, as it turns out, the labor is less expensive in Poland, however the parts not always. I found a shop, that would revive the ST, but they got busy, and I ended up repairing the bike myself, with the help of my cousin, who owns a car repair shop. The moto mechanic rebuilt the fork, and did some carb work and synched them.
Surprisingly, the gas in the tank was quite clean and good. It was dried out and gooey in the carbs. With the new battery, the bike fired up quite easily, but ran only on two cylinders - after 17 years ! And the disassembly began.
I knew about the obvious repairs I would have to do, but there were more, and more, and more… issues that needed to be addressed . The first, even before the battery, was the fuel pump. The original didn’t work. And I went from the front to the back, and from the top to the bottom.
One hiccup were the tires - the OEM sizes not easily available here. But thanks to this forum, I learned that the 120 tire will fit the rim and the bike, and I knew the 170 would fit the rear. It took me a while, with some mistakes I made - and it extended the time of the repair. But the bike runs quite well now, although it’s thirstier than I remember from the past. Some may be the result of the mechanic’s adjustments to the carbs - he enriched the fuel mix, and maybe the Chinese carb repair kits, came with the larger jets. I will deal with that later. I also need to repair couple of cracks in the bodywork, I believe from the shipping.
I will put the whole list of the repairs, if anyone is interested.
One other item remaining not fixed is the Progressive 420 shock. I don’t remember when I bought it, but I know it didn’t have many miles on it. It showed the signs of an oil leak , and it turned out, that the gas bladder deteriorated inside the shock, and the oil seeped through the valve. The mechanic worked on repairing it , but without success . Unfortunately I was brushed off by Progressive, when I inquired about maybe part available to purchase. No support from them whatsoever… So a new shock is on the horizon.

I hope this wasn’t too long of a post, but wanted to share with you the experience.
And I am glad to ride the ST again. 😎👍🏻


Cheers,
Peter
 

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I like those Givi side cases. The biggest enemies of any motorcycle (or vehicle in general) are time and lack of use. Good job getting it back on the road. The question usually asked is ‘was it worth the effort?’ I’d give a solid yes in this case.
 
I was able to rebuild the ST, with a great help from my cousin, and the mechanic in a couple of crucial issues.
But my big thank you, goes to the experience and the advise of this forum’s members, as I was able to find help in specific posts - THANK YOU 😊

Here is what was done to the ST :

Pirelli Angel GT tires (120/70-18 and 170/60-17)
New EBC brake pads (142 HH)
Cleaned and rebuilt front calipers - they were in a very bad shape
Spiegler braided brake and clutch lines ( fr and rr brake
New brake fluid
Rebuilt fork with 1.2 kg springs (Sonic)
All Balls steering head roller bearing
Cleaned and rebuilt brake an clutch master cylinders
Cleaned and rebuilt the clutch master cylinder - very bad shape
New timing belt installed
New coolant
New silicone radiator hoses kit installed
Cleaned thermostat housing, new o-ring
New thermostat
Cleaned water pipe joints, new o-rings
New water hoses
New carburetor insulators
New carburator rebuilt kits
Cleaned and synchronized carburators
New Air filter
New fuel filter and carburator fuel lines
New fuel pump
Repaired regulator-rectifier plug
Replaced exhaust gaskets
Colector and mufflers cleaned and painted
Fixed a small leak of the alternator oil, new o-ring
Cleaned and rebuilt the rear brake master cylinder
New lube and grease, new o-rings at the final drive
Cleaned and rebuilt the rear caliper
New rear brake pads…

Many hoses were in a bad shape, brittle, cracking. The old coolant an brake fluid clogged the respective passages, pumps and calipers.

All better now 😎
 
I like those Givi side cases. The biggest enemies of any motorcycle (or vehicle in general) are time and lack of use. Good job getting it back on the road. The question usually asked is ‘was it worth the effort?’ I’d give a solid yes in this case.
Thank you.
When I got the bike initially , it didn’t have the OEM saddlebags. Since I had some GIVI parts , and the E-41 bags on my XX at the time, I built my own mounts, and just switched the bags between the bikes. 🙃

The ST photos below , are from 2006/2007…
 

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