CYLI NDER  HEAD COVER INSTALL ATI ON

I nstall  the  cylinder  head  cover  and  tighten  the bolts.

 

TORQUE: 8-12 N m

(0.8-1.2 kg-m,6-9 ft-lb)

 

Install  the  valve  adjuster  cap  and  cover onto the cylinder head.

 

I nstall the 0-ri ngs to the water pipes and install  me water pipes into the cylinder heads.

VT500C

(1) 6 mm BOLTS

\ .

(21 6 mm NUTS          (3)  6 mm SH BOLTS

 

 

(1) VALVE ADJUSTER COVER

 

(21 BOLTS

 

 

 

 

CY LINDER/PISTON

VTSOOC

CYLI N DER REMOVAL

Remove the cylinder heads (Section 10).

 

Remove  rhe  gaskets  and  dowel  pins and  the cam chain guide.

 

 

(21 DOWEL PINS               (3) CAM CHAIN GUIDE

 

 

Remove  the cam  chain  tensioner bolt and sealing washer.

 

Remove the cam chain tensioner.

 

 

Remove the wa ter pipe bracket bolts.

 

(21 SEALING WASHER

 

 

(t ) (RIGHT SIDE)                     (2) (REAR SIDEl

 

 

 

Remove the water pipe bracket bolts. Remove  the  right  and  l eft water  pipes cyl inders by pulling them out by hand.

 

 

from the

 

Remove the Cl-rings from the wate r pipes. Remove the cylinders.

 

Remove the gaskets and dowel pins.

 

Clean  the top of  each  cylinder tJiorough ly with  a

gasket scraper.

 

NOTE

Avoid damaging the gasket surface.

The  gasket  will  come  off  easier  if  it  is soaked in solvent.

111 GASKET

 

 

CYLINDER  INSPECTION

 

Inspect the cvlinder bores for wear or damage.

 

Measure  the cylinder  1.0. at three levels in the X and Y axis.

 

SERVICE LIMIT:71.17 mm (2.802 in)

 

Calculate the taper and out of round.

 

SERVICE LIMITS :

Teper:              0.05 mm (0.002 in) Out of r04.l nd : 0.05 mm (0.002 in)

 

 

Inspect the cylinders for transverse warp11ge across the  top.

 

NOTE

SERVICE LIMIT:0.10 m m (0.004 in)

 

PISTON REMOVAL

Place  a shop towel  into the crankse and remove the piston p in cl ips .

 

NOTE

IDo not let the clips fall into the crankcase.           

Push the piston pin out and remove the piston.

 

 

Remove the oil jet and check for cloggl ng. Check the O·rlng for damage or deterioration.

 

 

PISTON/PISTON RING INSPECTION

 

Mea!Ure the piston ring.to-groove clearance.

 

SERVICE LIMIT:

TopfSecond : 0.10 mm (0.004 In)

 

 

Remove the piston rings and mark them to indicate the correct cylinder and piston position for re­ assembly.

 

Inspect the piston for cracks or other damage and the ring grooves for excHslve wear or carbon builO. up.

(1) OILJET

(2) O·RING

 

 

Me11ure the top and second piston ring end gaps; using a piston, push the ring into the cylinder squarely and melce the measuremen t

 

SER VICE LIMIT:

Top/Second :

011 lsld• rail):

 

0.50 mm (0.020 in)

1.10 mm (0.043 in)

 

 

 

Measu re the piston 0.0.

 

NOTE

 

Take measuremenu 10 mm (0.4 in) from the bottom, and 90° to the piston pin hole.

 

SERVICE LIMIT :70.84 mm (2.789 in)

 

Calculate the piston·to-cylinder clearance.

 

SERVICE LIMIT:0.32 mm (0.013 inl

 

Measure each piston pin hole 1.0.

 

SERVICE LIMIT :18.05 mm (0.711 in)

 

Measure ea<:h piston pin 0.0.

 

SERVICE LIMIT: 17.80 mm (0.701 in)

 

Calculate the piston pin to piston clearance.

 

SERVICE LIMIT:0.25 mm (0.010 in )

 

 

 

CYLINDER / PI S TON

H ONDA

VT500 C

PI STON RING INSTALLATION

Clean the piston domes, ring lands, and skirts.

 

NOTE

Insert the outside surface of the ri ng into the proper ring groove and roll it around in the groove to make sure that the ring has a free fit around the piston's circumference.

 

 

Carefully  install  the  piston  rings onto the piston with the mark ings facing up.

 

NOTE

Be careful not to damage the piston and piston rings during assembly.

 

Stagger  the  ring end gaps  180° apart  from each other as shown.

 

NOTE

To install the oil ring, i nstall the spacer first, then install the side rails.

 

After  installing  the  rings, check  that  they  rotate freely in their grooves without sticking.

 

 

 

 

,..,.

 

(1) TOP R ING

ii;.;j',&11""",         (2)  SECON 0 R ING

 

(3)

---;rQ..--

SIDE RAIL }

(4) SPACER           (6) OIL R ING 11"",'  - (5) SIDE RAIL

 

CY LIND ER /P I STON

PISTON  INSTALLATIO N

I nstall the oil jets . NOTE

Before installing the oil jets. make sure that the O·rings are installed on the jets.

 

 

Coat the rod small end wi th molybdenum disulfide grease. Assemble the piston and connecting rod wi th the piston and piston pin clips as shown.

 

NOTE

Install the pistons with the marking "IN " facing towards the inlet side.

After installing the piston pin clips, make sure that they are seated properl y and not aligned with the cutout in the piston.

Do not l et the piston pin clips fall into the

crankcase.

 

CYLINDER INSTALLATIO N

I nstall  the gasket and dowel pins.

H ONDA

VTSOOC

CYLINDER/PISTON

 

PISTON INSTALLATION

I nstall the oi l jets.

 

NOTE

 

Before installing lhe oil jets, make sure lhat the 0-rings are installed on the jets.

---'--'- ---'

 

 

Coat the rod small end with molybdenum disulfide greue.Amble the piston and connecting rod with the piston and piston pin clips as shown.

 

NOTE

 

CYLINDER INSTALLATION

I nstall the gasket and dowel pi ns.

Q\ H ONDA

VTSOOC

CYLINDER/P ISTON

 

Coat the cylinders, piston  rings/grooves and pistons with oil.

 

I nstall the cylinder over the piston while compressing

the piston rings.

 

Be sure each assembly  is  returned  to  i ts original posi tion os noted during removal.

 

NOTE

(:::J\ H O NDA

VT500C

(1) PISTON RING COMPRESSOR

07954-2830000

(2) PISTON

 

 

Apply oil to new water pipe 0-rings and place them on the water pipes.

Connect the water pipes to rhe cyl inders.

 

I nstal l  the water pi pe clamp bolts, tightening them securely.

 

 

(1) (REAR SIDE)                    (2)(RIGHT SIDE)

 

CY LINDER/PISTON

Q\ H O N'DA.

VTSOOC

I nstall the cam chain guides.

 

NOTE

(1) BOSSES (2) CAM CHAIN GUIDE

 

 

 

 

I nstall the tensioner bolts and sealing washers while pulling up on the tensioners.

 

(1) TENSIONER

 

(2) TENSIONER BOLT

 

 

I nstall the dowel pins and a new gasket.

Clean  the cylinder  contacting f eces of  the cylinder heads of gasket material and carbon deposits.

I nstall the cylinder heads (Page 10.18).

(1) GASKET

 

35-45 N·m (3.5-4.5 kg·m, 25-33 ft-lb)

 

 

8 mm BOLT

20-25 N·m

(2.0-2.5 kg m. 14-18 ft·lbl

 

 

0

8 mm BOLT

20-25 N·m

@ '

• (jj                 ··••.•.''-'""'"

 

(j

"f4l'-----6 mm BOLT

8-12 N·m

(0.8-1.2 kg·m,6-9 ft·lbl

 

CRANKCASE SEPARATION

The following parts must be removed before dis­ assembling the crankcase.

Water pump and water pipes(Refer to section 6) Clutch                 (Refer to section 7)

Gearshift linkage                 (Refer to section 9)

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