Honda ST1100/ST1100A & 2003 ST1100P Service Manual Set (P/N 61MY311)

Use the ST1100P addendum for Police-model differences and the base manual for service procedures and data not repeated there.

Additional reference required: Honda specifies using the base manual with the separate Common Service Manual, which is not included. Cross-references cover tire removal and remounting, battery testing and charging, oil-pressure checks, selected switch and sensor tests, standard brake bleeding, and portions of final-drive backlash and tooth-contact inspection.

Base-file omissions: Printed page 5-7 and pages 13-9 through 13-30 are absent. The latter gap removes the continuation of LBS front-wheel removal and the front-wheel disassembly, fork removal/disassembly/assembly, and steering-stem procedures listed in the contents.

PDF Search, Navigation, and Wiring Detail

Text search and small labels: Neither PDF supports text search or has embedded bookmarks. Zooming is needed for small wiring labels; fine lettering in the base manual is faint in places.

The ZIP download contains two printable English PDFs with 472 pages total. That total includes the base manual’s five front-matter pages and three duplicate pages, plus the addendum’s cover, introductory page, and memo page.

Engine, Brake-System, and Police-Equipment Coverage

The following selected topics outline the contents. Other sections cover oil-pump disassembly and combination-meter service.

• Engine and drivetrain: Engine removal and installation, cylinder-head disassembly, valve-clearance service, timing-belt and pulley work, clutch overhaul, transmission service, and final-drive assembly.

• Fuel and emissions: Carburetor separation and overhaul, synchronization, pilot-screw and high-altitude adjustment, plus PAIR and EVAP component service and hose routing.

• Cooling system: Coolant draining, radiator removal and disassembly, water-pump replacement, reserve-tank removal, and thermostat removal and installation.

• Chassis and brakes: Body panels and exhaust, rear-wheel disassembly, suspension service, brake master cylinders and calipers, and LBS fluid filling and bleeding.

• ABS/TCS diagnosis: Pre-start self-diagnosis, problem-code retrieval and clearing, wheel-sensor air-gap inspection and shim adjustment, and front/rear modulator replacement.

• Electrical testing: Charging-system checks for early and later builds, ignition fault tracing, starter-motor service, and lights/meters/switches inspections.

• ST1100P equipment: Police-specific bodywork procedures, lighting and voltmeter service, equipment wiring locations, cable routing, and a complete ST1100P wiring diagram.

Honda wrote these manuals for readers who already have basic Honda motorcycle maintenance knowledge. The procedures suit technicians and experienced owners comfortable with factory service information, measuring equipment, and specialty tools.

Internal Engine and Drivetrain Repair

The service notes distinguish in-frame work from jobs requiring engine removal, helping you assess workshop scope before disassembly. The transmission can be removed as a unit without separating the crankcases; crankshaft, connecting-rod, piston, and starter-clutch work requires deeper engine disassembly.

Illustrated procedures and supporting step-by-step instructions cover crankcase separation, primary-damper-shaft service, timing-belt replacement, clutch lock-nut work, and final-drive assembly. Color-coded bearing-selection tables support crankshaft and connecting-rod bearing replacement.

The timing-belt section warns that turning the camshafts with the belt removed can damage valves and piston domes. Incorrectly positioned bearing inserts can block oil passages and lead to engine seizure.

Chassis Service and Brake Variants

Handlebar and anti-dive procedures remain included, along with shock-absorber and swingarm service. The linked-brake sections address the secondary master cylinder, delay valve, and proportional control valve, with separate lever- and pedal-circuit bleeding instructions.

ABS/TCS Diagnostics and Workshop References

Separate chapters address 1992–1995 ABS/TCS and post-1995 LBS-ABS/TCS systems. Their pump/solenoid and motor-driven modulator arrangements use different diagnostic paths, helping you select the appropriate checks before replacing components.

System wiring locations, connector and terminal views, Symptom-to-System charts, and fault-isolation flowcharts support diagnosis and post-repair self-diagnosis. Graphics include the cooling-system flow pattern, TCS circuit diagram, LBS hydraulic layout, and standard-model wiring diagrams divided by production period.

The tool references identify valve spring compressor 07757-0010000, pinion joint holder 07924-ME40000, pinion retainer wrench 07910-MA10100, oil seal driver 07965-MC70100, and shock absorber compressor 07GME-0010000.

Component-specific torque tables, capacities, pressure specifications, wear limits, clearances, adjustment data, and electrical test values accompany the relevant systems.

ST1100P Bodywork, Routing, and Electrical Equipment

The addendum details the seat and seat cowlings, saddlebag and amplifier stays, fairing pockets, instrument panel, rearview mirror, and front strobe-lamp stay. It also covers headlight aim, rear turn-signal and brake/taillight bulbs, and voltmeter removal and bulb replacement.

Seven printed routing pages identify the bank-angle sensor, siren speaker, strobe lamp, headlight and voltmeter relays, Police switch groups, optional-equipment connectors, and fuel, ignition, EVAP, and PAIR routing. The base manual adds 20 printed routing pages for its Standard, ABS/TCS, and LBS-ABS/TCS configurations.

Eleven printed specification pages provide Police-model data. Identification illustrations cover the VIN, engine, frame, carburetors, and color label; emissions information includes the high-altitude update label and California vacuum-hose routing diagram.

Brake, cooling, fuel, and electrical work can involve pressurized fluid, hot coolant, gasoline vapors, or sudden motor operation, so the model-specific safety notes and required test equipment should be followed throughout any repair.

Sample Valve-Clearance and Cooling Specifications

For valve-clearance inspection with the engine cold, below 35°C/95°F, the base manual specifies 0.13–0.19 mm intake clearance and 0.22–0.28 mm exhaust clearance. Its maintenance section also explains shim selection.

The ST1100P cooling specifications list radiator-cap relief pressure at 108–137 kPa (16–20 psi) and thermostat opening temperature at 80–84°C (176–183°F).