RIGHT CRANKCA SE COVER REMOVAL

Drain oil from the engine (page 2·3).

Remove the exhaust pipe and brake pedal {pa,ge 5 2). Remove the brake pedal shaft bracket.

 

 

Place  a jack  or other adjustable support under the engine to support it.

 

Remove the right sub-frame. Disconnect the clutch cable.

 

 

Remove the right cran kcase cover, gasket andl dowel pins.

 

(1) BRAKE  PEDAL (2) EXHAUST PIPES

 

(1) CLUTCH CABLE

(2) SUB-FRAME

 

 

 

CLUTCH

H O NDA.

VT500C

CLUITCH LIFTER ARM D ISASSEMBLY

 

Remove the lifter rod and circlip. Remove the lifter arm and return spring.

NOTE

Ii nstall the retum spring as shown .                             

 

CLUTCH

(!IBEARING

 

(2) LIFTER PLATE

 

(3) PLATE "A"

 

 

(4) DISC "A"

 

 

(5) CLUTCH OUTER GUIDE

 

 

(16JOIL PUMP DRIVE SPROCKET

 

 

(13) PRESSURE PLATE

(14) ) WASHER

 

 

(9) CLUTCH CENTER

 

 

 

 

CLUTCH

r::iJ\ H O NDA

VTSOOC

CLUTCH REMOVAL

 

Remove the lifter plate bearing.

Remove  the  four bolts  in a crisscross pattern  in

2-3 steps.

 

Remove the clutch lifter plate and clutch springs.

 

 

CLUTCH SPRING INSPECTION

 

Measure the clutch spring f ree length.

 

SERVICE LIMIT :39 mm (1.53 in)

 

Replace  any  spri ng  that  is shorter than the service limit.

 

 

Hold  the  clutch  center  with  the  Clutch  Center Holder  (07923-KE 10000).

 

Remove the lock nut and lock washer.

 

Remove the clutch center, damper seat, damper spring. clutch disa and plates and  pressure plate as a unl L

 

 

(2) BOLT         (3) LIFTER PLATE (4) BEARING

 

 

 

(1) PRESSURE PLATE (21CLUTCH CENTER

 

 

 

 

CLUTCH

H O NDA

VT500 C

Remove the washer and clutch outer.

 

CLUTCH DISC INSPECTION

 

Replac:e the clutch discs if they show signs of scor­ ing or discoloration.

 

Measu re the disc thickness.

 

SERVICE LIMITS:

DISC A: 2.30 mm (0.090 in)

DISC B 2.60 mm  (0.102 in)

 

Replace  the  discs  If  they  are  thinner  than  the

service limits.

 

 

PLATE INSPECTION

 

Check for plate warpage on a surf ace plate, using a feeler gauge.

 

SERVICE LIMIT:  0.3-0 mm (0.012 in)

 

(2) WASHER

(1) CLUTCH OUTER

 

 

 

CLUTCH

H O NDA

VT500 C

INSPECTION CLUTCH OUTER

Chock  the sl01s in the clutch  outer for nicks, cuts or Indentations mede by the friction discs.

 

Measu re the clutctl outer 1.0.

 

SE RVICE LIMIT:32.10 mm (1.263 in)

 

 

Check  the clutch  outer bushing for score marks or other damage.

 

 

CLUTCH OUTER GUIDE

 

Measure  the  1.0. and 0.0. of  the clu tch  outer guide.

 

SERVICE LIM IT:

1.0. 22.09 mm (0.889 In)

0.0.  31.98 mm (1.259 in)

 

 

CLUTCH ASSE MBLY

Install the clutch outer guide over the mainshaft. Align the grooves in the clutch outer with the boss

on  the  oil pump drive sprocket while tu rning  the

sprocket  wim  the  chain  and  pushing  the clu tch outer.

 

 

 

(l ) BOSSES

 

 

GUIDE

 

 

 

Install the washer over the mai nshaft.

 

 

I nstall the damper spring and seat, and clutch plate B in the' clutch center.

 

NOTE

 

Note direction  of  the spring  seat, spring .and plate B.

 

 

I nstall the clutch discs, clutch plates and pressure plate on the clutch center and install them on the clutch outer  together.

 

NOTE

Stack  the  discs and  plates  alternately  as shown.

Coat new clutch discs with engine oil.

 

 

Install the lock washer making sure the "OUT SIDE" mark faces out.

 

(1) WASHER

 

C L U T C H

VT500C

Hold the clutch center with the Clutch Center Holder (07923-KE 10000).

Tighten the lock nut.

TORQUE: 65-75 N·m

(6.5-7.5 kg-m, 47-54 ft·lb)

 

Install the clutch springs, lifter plate and lifter plate bolts. Tighten the bolts in a crisscross pattern in 2-3 steps.

 

I nstall the bearing into the lifter plate.

 

 

P R IMAR Y GEAR

R EMOVAL

 

Remove the right crankcase cover (page 7-3).

Remove the clu tch (page 7-5).

Remove the top and bottom pulse generator pick up. Hold the pri mary gear wi th the gear holder (07923- ME90000) and remove the bolt.

 

Remove the pulse generator plate and primary gear from the cran kshaft.

 

(1) LOCK NUT

 

 

 

(1) BEAR ING   (4) LIFTER PLATE

 

 

(1) PRIMARY GEAR

{2) BOLT (3) PULSE GENERATOR PLATE

CLUTCH

VTSOOC

INSTALLATION

 

Install the primary gear.

 

Align the center of two pulse generator plate teeth with the flat of the crankshaft serrations and install the plate.

 

Measure  the pu lse coil  air gap and  adjust if neces­ sary  (page 19-4).

 

AI R GAP: 0.3-0.9 mm  (O.Gl-0.04 in)

 

 

I nstall  the primary  gear holder  (07923-ME90000). Tighten th e primary gear bolt.

TOR QUE: 80-100 N·m

(8.0-10.0 kg ITli,58-72 ft-lb)

 

R emove the gear holder and install the pu l se genera­ tors and  clutch.

 

 

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