Based on the feedback from mechanic Thomas Kronberger, long time ST owner Martin Brunner recommends these maintenance tasks to be carried out in addition to the Honda recommended regular maintenance.

Disclaimer:

These are the maximum recommended intervals, items could fail earlier, more frequent inspection will help to avoid failures.

12.000Km / 8,000Mile intervals:

• Inspect and lubricate the final drive spline (see diagram on the right, use molybdenum disulfide grease), replace when worn. (This should also be done every time the rear wheel comes off)
• Inspect the rear wheel rubber dampers (position 1 on the Rear wheel diagram), replace when worn.

36.000Km / 24,000Mile intervals:

• Inspect wheel bearings, replace if necessary.
• Inspect the front fork slider bushings (position 13 & 14 on the Front fork diagram, or for the ABS2 version position 16 & 17 on the Front fork ABS2 (1996 and later) diagram), replace when worn.

  How to check:

  • Handlebars in straight forward position, move wheel back and forth, check for movement of the fork tubes in the fork casings.
  • Handlebars fully turned one way, grab the front wheel and try to twist it further, check for movement of the fork tubes within the fork casings.
• Replace front fork oil. Rinse out the fork leg casings with petrol to remove any muck that accumulates at the bottom before filling with new oil.
• Inspect the rubber boots (position 7 on the Clutch master cylinder diagram) between clutch and brake levers and the hydraulic master cylinders, replace when worn.
• Inspect and lubricate the push rod (position 1 on the Clutch master cylinder diagram) between clutch and brake levers and the hydraulic master cylinders, replace when worn.
• Inspect and lubricate the clutch and brake lever's cylindrical brass inserts (position 2 on the Clutch master cylinder diagram), replace when worn.
• Inspect the clutch and brake levers, replace when the hole for the brass inserts has worn oval.
• Inspect and lubricate the ball joints on the gear shifting levers.
• Inspect and lubricate rear pedal brake light switch.
• Lubricate the speedo gear (left side front wheel).
• Inspect wiring connectors and fuse box for corrosion and bad contacts.

  Tips:

  • Molten/deformed plastic (connectors, fuses etc.) indicates a bad electric contact.
  • Make sure the contact pressure of connectors and fuse holders is firm, squeeze the connector "shoe" with a pair of pliers if the fit is loose.
  • Clean electric contacts mechanically when you can, don't use contact cleaning spray unless you cannot clean contacts mechanically.
  • Only use regular contact cleaning spray when you can completely remove the residue with for example compressed air, a residue will cause corrosion on the long term. A safer alternative is so called "Tuner" contact cleaning spray (harder to find, try electronics stores), this type of contact cleaner evaporates cleanly. Only use contact cleaner on switches, and only use it when switches actually cause problems (not preventively). Note that "tuner" contact cleaner also dissolves necessary switch gear lubricants.
  • Vaseline or silicone spray lubricates switch gear and provides some corrosion protection for electric contacts.
• Inspect the carburetor insulators (position 4 on the Cylinder head left & Cylinder head right diagrams)

  More info:

  Enclosed between the 2 cylinder rows, the rubber insulators get hot which can cause them to get rock hard (especially in hot climates) resulting in air leaks that cause vibrations and reduced performance. See the Replacing the carburetor insulators guide for pictures of this job.

• Inspect the water pump (position 3 on the Water pump diagram), replace when it shows signs of leakage.
• Inspect the 2 elbow joint O-Rings of the internal cooling bypass (position 11 on the Water pipes (1996 and later) diagram).

  Visual check:

  If you remove the tank and peek underneath the carburetors and see white crystals growing around those elbows, you have an indication that the O-rings are beginning to fail, before you have a massive leak there.

120.000Km / 80,000Mile intervals:

• Replace the radiator fan switch (position 21 on the Radiator & fan diagram).
• Replace the radiator cap (position 8 on the Radiator & fan diagram).
• Inspect the swing arm, use something blunt like the handle of a screw driver to check if any parts of it have rusted through, replace when necessary.

Every 4 years:

Replace brake and clutch lines (if they are original Honda, doesn't apply to to braided after market lines).