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EN G INE R E MO VAL/I N STA LLA T I ON





VTSOOC


EN G INE REMOVAL

Place the motorcycle on its center stand. Remove the seat and fuel tank.

Remove the left and righ t frame side covers.

 

Drai n  the  engine  oil  (page 2-3) and  the coolant (page 6-3).

 

 

(2) SIDE COVER


 

 

Remove the radiator (page 6-6).

 

Remove the rear brake pedal.

 

Remove the exhaust pipe flange nuts.

 

Loosen  the exhaust pipe clamp bolts and remove the exhaust pipes.


 

 

(1) RADIATOR

 

(1) BRAKE PEDAL

 

(2) CLAMP BOLT     (3) EXHAUST PIPE


 

 


Loosen the muffler clamp bolts and remove  the muffler mount bolts.

 

Remove the mufflen;.

 

Remove  the  power  chamber  mounting bolts  and power chamber.

 

Disconnect  the  alternator and neutral/OD switch wire coupler (page 1 10).

 

 

Remove  the  air cleaner connecting tube  and car· buretor  (page 4·3).

 

Disconnect the tachometer  ca'ble from the engine. Remove the spark plug caps.


 

(1) MUFFLER              (2) POWER CHAMBER

 

 

 

(1) TACHOMETER

CABLE                 (2)CAR BURETOR









E N G INE  RE MOV AL / IN S T A LL A11'10 N

Disconnect  the water  hoses from  the cylinder head. Disconnect the  crankcase  breather tube.

Disconnect the pulse generator wi re coupler.

 

Remove the left crankcase rear cover. Remove the gear shift arm pinch bolt. Remove the left footpeg mounting bolts.

Remove the left foo1pe9 and mhifl linkQge  s

a set.



VT500C

(2) PULSE GENERATOR

(1) WATER HOSE  WIRE COUPLER

 

 

 

(1) GEARSHI FT(2)GEARSHI FT

LINKAGE   ARM     (3) PINCH BOLT


 

 


(4)  GEARSHIFT PEOAL


(51LEFT FOOT PEG


{6)LEFT

CRANKCASE REAR COVER


 

 

Remove the rear wheel (page 16-3). Remove the final gear case {page 14-3).


 

 

Rem ove the brake pedal pivot.

 

Discon nect the clutch cable by loosening the h andle­ bar adjuster.

Disconnect the starter motor cabl e.

 

Ploce a floor jack or other adjustable support unde r the engine.

 

NOTE


 

 

(1) BRAKE PEDAL PIVOT

 

 

(2) STARTER MOTOR CABLE

 

 

(1) ENGINE HANGER BRACKET


 

Remove the righ t sub·frame. Remove  the engine hanger  bracket.

Remove the engine moun ting bolts.

 

Remove th e engine  from the  right side while dis· connecting the drive shaft universal joint from the engine.

 


 

ENG INE INSTALLATIO N

Engine installation is essentially the reverse of re· moval. Use a floor jack or other adjustable support to carefully manuever the engine into place.

 

CAUTION

 

 

Tighten the all fasteners to the specified torque:

 

ENGINE MOUNT BOLTS:

8 mm BOLT: 20-30 N·m

(2.0-3.0 kg·m,14-22 ft-lb)

10 mm BOLT: 45-60 N·m

(4.5-6-.0 kg-m,33-43 ft-lb) SUB-FRAME MOUNT BOL.T AND NUT:

SOCKET BOLT: 30-35 N·m

(3.0-3.5 kg-m,22-25 ft-lb)

FLANGE NUT: 20-24 N·m

(2.0-2:.4 kg·m, 14-17 ft-lb)

 

NOTE

 


 

Install the rear cylinder exhaust pipe to the chamber bolt loosely. Install them to the flame.

Install the remaining exhaust pipe and mufflers. NOTE


EXHAUST PIPE JOINT NUT:

8-14 N·m (0.8-1.4 kg-m,6-10 ftlb) EXHAUST PIPE CLAMP BOLT:

20-28 N·m (2.0-2.8 kg-m,14-20 ft-lb) MUFFLER CLAMP BOLT:

20-28 N·m (2.0-2.8 kg-m, 14-20 ft-lb)


 

 

COOLING SYSTEM















H ONDA

VT500C







SYSTEM  TESTING

COOLANT

 

Test the coolan t mixture with an anti-freeze tester. For maximu m corrosion protection, a 50-50% solu­ tion of ethylene glycol and distilled water is recom­ mended .

 

RADIATOR  CAP INSPECTION

 

Pressure test the radiator cap. Replace  the radiator cap if i t does not hold pressure, or if relief pressure is too high or too low. I t must hold specified pres­ sure for at least six seconds.

 

NOTE

 

Before installing  the cap on the tester, apply water to the sealing surfaces.

 

RADIATOR CAP RELIEF PRESSURE:

73.6-103.0 kPa (0.75-1.05 kg/cm 2 ,

10.7-14.9 psi)

 

 

Pressu rize the radiator, engine and hoses, and check for leaks.

 

CAUTION

 

Repai r or replace components if the system wi ll not hold speci fied pressure for at least six seconds.


 

 

 

(2) COOLING SYSTEM TESTER


 

 

COOLING SYSTEM

 



COOLA NT REPLACEM ENT

CAUTION

 

T he engine must be cool before ser11icing the coo/Ing system, orsevere scalding may result.

Remove  the  fuel tank  rear moun ting bolt  and raise the f ront of the fuel tank.

 

Remove the steering stem cover. Remove the radiator f iller cap.

 

 

Remove the drain bolt located at the water pump and drain the system coolant.

 

Reinstall the sealing washer and bolt.

 

 

Loosen  the air bleed bolt located at the l eft of the thermostat housing.

 

Fill  the system with  a 50-50 mixture of disti lled water and ethylene glycol.

 

Reti\jlten the bleed bolt.


r::tiJ\ H O NDA

VTSOOC

(1) DRAIN BOLT WITH SEALING WASHER


 

Bleed air from the radiator.

• Start the engine and  let it ru n  un til there  are no air  bubbles in  the  coolan t,  and  the  level  sta-

bilizes.

Stop the engine and add coolant u p to the proper level if necessary.

R einstall the radiator cap.

Check the level of coolant in the reserve tank and

f ill to the correct level i f i t is low.                                    (2) BLEED BOLT


 

THERMOSTAT

REMOVAL

 

Turn the fuel valve OFF. Remove the seat and fuel tank.

Remove  the  coolant  drain  bolt,  and  drain  the coolan t (page 6 3).

 

Loosen the water hose clamps.

 

RemOYe the air cleaner connecting tube.

 

 

(2) CLAMPS

 


 

RemOYe the steering stem covers. Remove the turn signal relay.

Disconnect the temperature sensor wire.

 

Disconnect  the  overflow  tube  from  the  radiator filler neck.

 

Loosen the ignition coil bracket mou nti ng bolts.

 

Loosen the radiator hose clamp.

 

Remove the bolt attaching 'the therm0stat housing and filler neck.

 

Remove the thermostat housing and filler neck.

 

Remove the two bolts and thermosta t cover.


(1) FILLER NECK MOUNTI NG

BOLT             (2)TURN SIGNAL R ELAY  (3) OVER FLOW TUBE

 

(4) IGNITION COIL BRACKET (5) CLAMP (6) THERMOSTAT MOUNTI NG BOLTS        HOUSI NG

MOU NTI NG BOLTS

 

 

(1 l COVER


 

 

Remove the thennostat from the housing.

 

 

INSPECTION

 

Visually Inspect the thermostat for damage.

Suspend the thermostat in heated water to check Its operation. Do not let the thrmostat or thermo­ meter touch the pan or false readings will result.

 

Replace the thermostat if the valve stays open at room temperature, or if it responds at temperatu res other than those specified.

 

Technical Data

St r l5 to open 80° to 84°C (17G0 to 183°F)
  Valve l ift 8 mm minimum (0.31 in) when heated to 9s°C (203°F) for five minutes.

 

 

INSTALLATION

 

Install the thermostat in the housing.

 

Install  a new 0-ring onto the cover, place the cover onto the housing and tighten the bolts.


 

 

(!)THE R MOSTAT

 

 

 

(1) 0-R ING

 

(2) THERMOSTAT


 

 

COOLING SYSTEM

 

Install a new O·ring onto the fit ler neck.

 

lnuall  the  thermostat  housing  in  the  frame  and install the filler neck.

 

Loosely, tigh ten the thermostat housing mounting bol ts.

 

Tigh ten  the  filler  neck  mounting bolt securely  to the Ignition coil bracket

 

Tigh ten the Ignition coil bracket bolts. Tighten the water hose clamp bol ts.

Con nect the temperatu re sensor wi re to the tempera· ture sensor.

 

Add coolan t In the system (page S.3).

 

I nstall  the air cleaner connecting tube and fuel tank. Install the steering stem cover.

 


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