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R IG HT CRANKCA SE COVER I NSTALLATI ON
Remove the gear holder tool and install the clutch. (1) PR IMARY GEAR
(2) PULSE GENE R ATOR PLATE
I nstall the dowel pins and a new gas·ket.
(2) OOWEL PINS
Ins tall the r igh t c ra nkcase cove r a nd t ight e n the cover bolts.
TORQUE: 8-12 N·m (0.8-1.2 kg m.6-9 f t-l b)
I nstall the sub-frame and ti ghten the bolts.
TORQUE : Upper: 30-35 N·m (3.0-3.5 kg-m, 22-25 ft-lb) Lower: 20-24 N·m (2.0-2.4 kg-m, 14-17 ft-lb)
Install and torq ue me engine mount nuts.
TORQUE: 45-·60 N·m (4.5-6.0 kg•m, 33-43 ft lb)
Install the exhaust pipe (page 5-6). Install the brake pedal shaft bracket. I nstall the brak e pedal.
Fill the crankcase with oil (page 2-3).
BRAKE PEDAL
ALTERNATOR/STARTER CLUTCH VT500C
8-12 N·m (0.8-1.2 kg-m, 6-9 ft-lb)
130-140 N·m (13.0-14.0 kg-m, 94-101 ft·l b)
STARTO R R EMO VAL Remove tho seat. Disconnect the al ternator cou pler.
Remove the rear cover. Remove the left foot peg and gear shift pedal.
Remove the alternator cover bolts and cover. Remove the gasket and dowel pins.
(2) GEAR SHIFT PEDAL (1) REAR COVER
(3) LEFT FOOT PEG
( 1) ALTERNATOR COVER
ALTERNATOR / S T A R TE R CLUTCH H O NDA. VT500C Remove the bolt anaching the alternator wire clamp and clamp.
R emove the stator mounting bolts and stator from the alternator cover.
FLYWH EEL REM OVAL Hold the flywheel wi th the flywheel holder and remove the flywheel bol t.
NOTE I The flywheel bol t has lef t-hand th re ads.
(2) FLYWHEEL HOLDER 07923-MESOOOO
Remove the flywheel wi th the rotor puller.
(1) ROTOR PU LLER 07733-0020001
(2) FlYWHEEL
ALTERNATOR /STARTER CLUTCH
STARTER CLUTCH DI S ASSEMBLY Remove the flywheel (page 8-3).
Remove the s.tarter drive and reduction gears, and gea r shafts.
Pull the starter driven gear toward you un til i t stops.. Then remove the needle bearing from the gear.
Remove the driven gear. H ONDA VT500C (2) STARTER (3) STARTER (1 ) NEEDLE BE ARING REDUCTION GEAR DR IVE GEAR
(4) STARTE'A DR IVEN GEAR (5) GEAR SHAFTS
Remove the three ton< bolts attaching the starter clutch to the flywheel and remove the starter clutch and clutch outer.
STARTER CLUTCH INSPECTION
Inspect the starter clutch for smooth operation. Check the rollers for excessive wear. Measure the starter clutch outer l.D.
SER VICE LIMIT:70.96 mm (2.794 in)
(1) ROLLER
(2) IF LYWHEEL (3) PLUNGE R (4)SPRING
Measure the driven gear 0.0.
SER VICE LIMIT:54.06 mm (2.128 in)
STARTER CLULCH A S SEMBLY Install the starter clutch and clutch outer onto the f lywheel.
Apply a locking agent to the three torx bol t threads and tighten the bolts using a Torx bit.
TORQUE: 18-25 N·m (1.8-2.5 kg·m,13-18 ft l b)
Install the starter driven gear and needle beari ng over the crankshaft.
Install the starter reduction gear, drive gear and shafts.
(2)STARTER (3) STARTER (1) NEEDUE BEARING REDUCTION GEAR DRIVE GEAR
(4) STARTER DRIVEN GEAR (5) GEAR SHAFTS FlYWHEEl IN S TALLATION I nstall the flywheel on the crankshaft while turning i t counterclockwise.
Apply LOCTITE® or equivalent to the bolt threads.
Hold the flywheel with the flywheel holder and torque the flywheel bolt.
TORQUE: 130-140 N·m (13.0-14.0 kg·m, 94-101 ft·lb)
S TATOR IN S TALLATION I nstall the stator on the alte rnator cover and tighten the three bolts.
I nstall the alternator wire clamp wi th the bolt.
Instal l the gasket and dowel pins.
Instal l the alternator cover in the reverse order of removal.
(1) FLYWHEEL HOLDER 07925-ME90000
(1) GASKET (2) DOWEL PINS
GEARSHIFT LINKAGE VTSOOC 8-12 N·m (0.8-1.2 kg·m, 6-9 ft-lb) 10-14 N·m (1.0-1.4 kg·m, 7-10 ft·lb) i{;)a:o:m
GEA RS HIF T LINK AGE VTSOOC |
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