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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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