Requisite Service

Install onto the end of the fork damper. Wrap vinyl tape around the fork tube top end to avoid damaging the oil seal lip during installation. Drive the slider bushing and oil seal into the slider using the fork seal driver (07947-KA50100) and * Be careful not to damage the fork tube sliding Pour in the fork fluid to the specified level before Wipe fluid off the spring thoroughly using a clean lint free cloth and install with the tightly wound coil end Install the stopper between the spring seat...

Service Information

Wait until the engine is cool before slowly removing the radiator cap. Removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding. Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes. If any coolant gets in your eyes, rinse them with water and consult a doctor immediately. If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately. If any coolant gets on your skin or clothes, rinse thoroughly with...

System Location

(4) ABS TCS WARNING LIGHT SWITCH (3) BATTERY REAR PUMP MOTOR RELAY (15) ABS MAIN RELAY Refer to section 2, (frame body panels exhaust system), for the parts that must be removed for sevice. For example (D ABS TCS WARNING LIGHT SWITCH -Maintenance part -Top shelter*-The parts that must be removed for service. ABS MAIN (1 OA) FRONT SOLENOID (10A) REAR SOLENOID (10A) REAR LIMIT SWITCH -R. side cover (page 2-2) ) ABS TCS WARNING LIGHT SWITCH -Top shelter (page 2-5) ) ABS WARNING LIGHT 2 -Inner...

General Safety

If the engine must be running to do some work, mark sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. Work in a well ventilated area. Keep cigarettes, flames or sparks away from the work area or where gasoline is stored. Gasoline is extremely flamable and is explosive...

Coolant Draining

* Wait until the engine is cool before servicing the cooling system. Removing the radiator cap while the engine is hot and the coolant is under pressure may cause serious scalding. For coolant replacement, refer to section 5 of the Common Service Manual. Remove the left and right middle fairings (page 2-8). Remove the radiator cap. Remove the radiator drain plug and gasket, and drain the coolant from the radiator. Remove the drain bolts and sealing washers from the left and right cylinders, and...

Maintenance Schedule

Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period. I Inspect and clean, adjust, lubricate, or replace if necessary. R Replace C Clean L Lubricate A Adjust The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more technical information and tools. Consult your authorized Honda dealer. I Every 100,000 km (60,000 mi), R Every 150,000 km (90,000 mi) * Should be serviced by an authorized Honda...

St1100 Coolant System

Passages blocked in radiator, hoses, oil cooler, or water jacket. Faulty temperature gauge or gauge sensor. Faulty cooling fan motor switch. Faulty pump mechanical seal. Damaged or deteriorated cylinder head gasket. Loose hose connection or clamp. Damaged or deteriorated hoses.

Timing Belt

Remove the reduction holder covers page 8-2 . Remove the timing hole cover page 3-5 . Check the timing belt for is cracked, damage or contamination with oil and or coolant while turning the crankshaft clockwise. If the belt cracks or damaged, replace it with a new one page 8-12 . If the belt is contaminated with oil and or coolant, remove the timing belt cover page 8-3 . clean the timing belt housing and pulleys thoroughly, then replace the belt with a new one.

Brake Pad Replacement

A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake assemblies. After replacement, operate the brake lever to seat the caliper pistons against the pads. The brake pads can be replaced without disconnecting the hydraulic system. Replace the brake pads as a set....

Crankcase Emission Control System

Exhaust Emission Control System

The crankcase emission control system routes crankcase emissions through the air cleaner and into the combustion cham- Exhaust Emission Control System Secondary Air Supply System SW, AR types only The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system. This charge of fresh air promotes burning...

Exhaust Pipe Installation

Make sure that the mounting collar is installed in position and loosely install the left exhaust pipe chamber to the frame with the 8 mm mounting bolt and washer. 2. Make sure that the exhaust pipe gaskets are installed in position, insert the left exhaust pipe flanges into the cylinder head and loosely install the joint nuts. 3. Insert the right exhaust pipe into the left exhaust pipe chamber. 4. Make sure that the exhaust pipe gaskets are installed in position, insert the right exhaust...

Troubleshooting

Summary of ABS pre-start self-diagnosis system The ABS pre-start self-diagnosis system diagnoses the electrical system as well as the hydraulic system operation in the modulator. When there is any abnormality, the problem and the problem part can be detected by outputting the problem code. After starting the engine, the ABS pre-start self-diagnosis system operates the pump motor and solenoid valve inside the modulator, checks the limit switch ON OFF condition with ECU and thereby it detects...

Carburetor Idle Speed

Inspect and adjust idle speed after all other engine adjustments are within specifications. Engine must be warm for accurate adjustment. Ten minutes of stop-and-go riding is sufficient_ Warm up the engine, shift the transmission into neutral and place the motorcycle on its center stand. Open the top shelter lid with the ignition key. Adjust the idle speed by turning the throttle stop control

Timing Belt Removal Installation

Honda Sabre Camshaft Installation

Perform this servicing while the engine is cold. For easy servicing, remove the spark plug. Be careful not to contaminate the timing belt with oil etc. Do not bend the timing belt excessively. Hold the crankshaft and remove the left driven pulley bolt, washer and guide. Loosen the timing belt tensioner bolt 1 4 1 2 turn, release the tensioner by turning the crankshaft counterckockwise while holding the right driven pulley, and temporarily tighten the tensioner bolt. Turn the crankshaft...

St1100 Hard Steering

Steering head bearing adjustment nut too tight Faulty steering head bearings Damaged steering head bearings Steers to one side or does not track straight Bent front axle wheel installed incorrectly Faulty steering head bearings Worn swingarm pivot bearings Lack of grease in speedometer gearbox Handlebar Cover Removal Installation Installation is in the reverse order of removal. At installation, align the pins with the hole in the lower cover and insert the tab into the latch securely.

Rear Wheel Disassembly Assembly

Replace the rear wheel damper rubbers as a set. Replace the wheel bearings as a set. For wheel bearing replacement, refer to the section 1 of the Common Service Manual. When the puiser ring is replaced, perform the wheel sensor air gap inspection page 16-51 ABS TCS model only after intalling the rear wheel.

Pilot Screw Adjustment

Honda St1100 Carburetor Adjustment

Adjust the pilot screws as follows NOTE Make sure the carburetor synchronization is within specification before pilot screw adjustment. The pilot screw are factory pre-set and no adjustment in necessary unless the pilot screws are replaced. Use a tachometer with graduations of 50 min-1 rpm or smaller that will accurately indiccate a 50 min-1 rpm change. A pilot screw wrench is necessary to turn the pilot screws. SW type only Pilot screw wrench 07 KM A...

Service Access Guide

The following shows the locations of the parts that must be removed for the maintenance items listed below. Refer to the Common Service Manual for items not included in this manual. Refer to section 2 frame body panels exhaust system , for the parts that must be removed for service. For example AIR CLEANER Contamination, clogging, replacement Maintenance part service items Top shelter The parts that must be removed for service. 5 SPARK PLUG Wear, damage, color Maintenance cover 4 HEADLIGHT...

Engine Mounting Bolt Tightening Procedure

Loosely install all engine mounting bolts, nut, sub frame bolts, nuts, and engine mounting brackets. Tighten the sub frame bolts in the sequence below. Tighten the 10 mm engine mounting bolts and J . Lengthen the adjusting collar on the 10 mm engine mounting bolt until the collar contacts with the engine and frame by turning the adjusting nut of the collar. Tighten the 10 mm engine mounting 8 and . Tighten the 12 mm engine mounting bolt 0 gt and nut Q . Tighten the adjusting collar lock nut....

Clutch Lock Nut Removal Installation Removal

Unstake the clutch lock nut with a drill or grinder. Hold the clutch center with the clutch center holder and remove the lock nut. Clutch center holder Clutch holder collar 3 pieces Lock nut wrench, 30 x 32 mm Extension bar 07 J M B M N50300 07LMB MT30100 07710 0020400 07716 0020500 Hold the clutch center with the clutch center holder. Clutch center holder 07JMB MN50300 Clutch holder collar 3 pieces 07LMB MT30100 Lock nut wrench, 30 x 32 mm 07716 0020400 Install a new kock nut and tighten it....

St1100 Pilot Screw Adjustment

Cam reduction gear shaft bearing shaft side installation Valve cotter removal installation Valve seat cutter, 24.5 mm 45 EX Interior cutter, 30 mm 60 IN, EX Master cylinder disassembly assembly Clutch lock nut removal installation Clutch lifter plate bearing removal Countershaft front bearing installation Ball race amp bearing driver attachment Shift drum rear bearing installation Countershaft rear bearing installation Pinion retainer wrench Pinion puller set Pinion puller base Pinion joint...

Carburetor Synchronization

Coolant Vacuun Cyncronization

Refer to section 2 of Common Service Manual for carburetor synchronization procedure. Synchronize the carburetor with the engine at normal operating temperature, transmission in neutral and motorcycle supported upright. Remove the left and right fairing pockets page 2-6 . Disconnect the No.3 cylinder vacuum tube from the auto fuel valve, apply vacuum to the auto fuel valve and pinch the tube with a clip. Connect the vacuum gauge adaptor to the No. 3 cylinder vacuum tube. Remove the vacuum tube...

Torque Values

6 mm bolt and nut 8 mm bolt and nut 10 mm bolt and nut 12 mm bolt and nut 5 0.5, 3.5 10 1.0, 7.2 22 2.2, 16 35 3.5, 25 55 5.5, 40 6 mm flange bolt 8 mm head 6 mm flange bolt 10 mm head and nut 8 mm flange bolt and nut 10 mm flange bolt and nut 4 0.4, 3 9 0.9, 7 9 0.9, 7 12 1.2, 9 27 2.7, 20 40 4.0, 29 Torque specifications listed below are for important fasteners. Others should be tightened to standard torque values listed above. Notes 1. Apply locking agent to the threads. 2. Apply oil to the...

Specifications

28 liters 7.40 US gal, 6.16 Imp gal Bore and stroke Displacement Compression ratio Valve train 73.0x64.8 2.87x2.55 1,084 cm3 66.1 cu in 10.0 1 Unit type, 3 main journals 92.0 kg 203 lb 1 90 4 270 3 90 2 270 4 cylinders, 90 V Constant velocity 4 carburetors 34.5 1.36 Multi-plate, wet Hydraulic operating 5 speeds 1.8292 75 41 2.8333 34 12 2.2666 34 15 1.5000 27 18 1.1428 24 21 0.9166 22 24 0.7586 22 29 Left foot operated return system 1 N 2 3 4 5 Ignition system Starting system Charging system...

Final Gear Case Assembly

Keep dust and dirt out of the gear case. Be careful not to damage the case and cover mating surfaces. Refer to section 15 of the Common Service Manual for the backlash inspection, the gear tooth contact pattern check and the ring gear-to-stop pin clearance check. If the gear set, pinion gear bearing, ring gear bearing gear case bearing and or gear case are replaced, install a 1.50 mm pinion gear shim and a 2.00 mm ring gear shim. The ring gear and pinion gear must be replaced as a set.

Lubrication Seal Points

Upper and lower crankcase mating surface Oil pressure switch thread Do not apply sealant near the rain journal bearings. Do not apply sealant to the switch thread head as shown Semi-circular portion of the cylinder head Valve stem valve guide sliding surface Camshaft journals, cam lobes and thrust surfaces Connecting rod bearing cap nuts Piston Timing belt idle pulley bolt threads Oil pump driven sprocket bolt threads Primary damper shaft bearing set plate bolt threads Timing belt tensioner...