OUTPUT GEAR CASE INSTALLATIO N

OUTPUT CASE INSTALLAT ION

I nstall the oil orif ice end dowel pi ns.

(1} DAMPER SPRING (2)DAMPER CAM

(4} DAMPER COMPRESSOR 07964-ME90000

Install the output gear case. Tighten the three bolts.

SHI FT FORK / SHIFT D RUM

GEA R SHIFT OR UM ANO SHIFT FOR K INSPECTION

Inspect the shift drum end for scoring, scratches, or eviden of insufficient lubrication. Check the shift drum grooves for damage.

Measure the shift drum 0.0.

SERVICE LIMIT: 13.90 mm (0.547 in)

Measure the right, center and eft shift fork 1.0. and the shift fork claw thickness.

SERVICE LIMITS:

1.0.: 13.037 mm (0.5133 in)

CLAW THICKNESS: 4.63 mm (0.182in)

(21

1.0.

( 1) SHIFT FORK

CRANKSHAFT/TRANSMISSION

VT500C

Check for scratches, scoring or evidence of insuffi cient lubrication on the shift fork shaft.

Measure the shift fork shaft O. D. at the right, center and left shift fork surfaces.

SERVICE LIMIT: 12.90 mm (0.508 in)

Install the R.L. forks facing as shown against the center shift fork.

CR A NKCASE BEA RINGS REPLACEM ENT

LEFT CRANKCAS E BEA RINGS

Heat the lef t crankcase around the mainshaft and countershaft bearings to 80°C ( 176°F).

CAUTION

Always wear gloves when handling a heated crankcase.

Remove the main and countershaft bearings with the following tools.

Bearing remover, 20 mm 07936-3710001

Drive a new bearing into the left crankcase with the following tools:

Driver A 07749-0010000

Attachment, 42 x 47 mm 07746-0010300

(2)COUNTERSHAFT BEARING

R IGHT CRANKCASE BEARINGS

Heat the ri\tlt crankcase around the mai nshaft, countershaft, output d rive shaf t and shift d rum bearings to 80°C ( 176°F).

CAUTION

Always wear gloves when handling a heated c rankcas e.

Remove the mainshaft and countershaft bearings with the following tools:

(2) OUTPUT DRIVE SHAFT BEARING

Bearing remover, 20 mm 07936-3710001

Remove the output drive shaf t arings with the following tools:

(3JSHIFT ORUM BEARING

(4) COUNTERSHAFT BEARING

Driver A

Attachment, 42 x 47 mm

07749-0010000

07746-0010300

Drive the new bearings into the right crankcase with the following tools:

Mai n shaft:

Attachment, 52 x 55 mm	07746-0010400
Pilot, 22 mm	07746-0041000
Driver A	07749-0010000

Cou ntershaft/output drive shaft:

Driver A	07749-0010000
Attachment, 42 x 47 mm	07746-0010300
Pilot, 20 m m	07746-0040500

TRANSMISSION INSTALLATION

I nstall the mai nshaft and countershaft assembly on the crankcase.

CR ANKSHAFT/TR ANSMISS I ON

H O NDA

VT500C

Install the shift forks with their marks facing toward the right crankcase.

Install the shift drum and slide the shift fork shaft throught the shift forks.

Assemble the crankcase (page 12-4) .

(2j SHIFT DRUM

8 mm:23-28 N·m

(2.3-2.8 kg·m, 17-20 ft lb)

10 mm: 45-50 N·m

(4.5-5.0 kg·m, 33-36 ft-lb)

•

fiJ

80.-100 N·m

(8-10 kg·m,

58-72 ft·lb)

100-120 N·m

(10-12 kg·m,

71-87 ft lb)

FIN A L D R I VE

FINA L DR IVE REMOVA L

Place the motorcycle on i ts center stand. Drai n the final gear oil ( page 2·9) and remove the rear wheel (page 16·3).

Remove the left shock absorber (page 16-10).

Remove the final gear case attaching nuts and remove the gear case from the swingarm.

DRIVE SHAFT

R EMOVAL

Separate the drive shaft from the gear case by gently revolving the shaft in a circu lar motion while tugging it sl ightly.

(2) NUTS

Ci!\ H O NDA

VT500C

(2) DRIVE SHAFT

DISASSEMBLY

Remove the spring, oil seal and stop ring from tha drive shaft.

NOTE

Replace the oil seal with a new one if it is removed.

ASSEMBLY

Place a new oil seal over the drive shaft.

I nstal I the damper spring and a new stop ring.

(1) OIL SEA L

(2) SPRING (3) STOP RING

FINAL DRIVE

UNIVER S AL JOI NT

A EMOVAUINSTA LLATION

Remove the swingarm (page 16-13).

Remove the un iversal joint from the engine output shaft. \

I nspect the universal joint bearings for excessive play or damage.

Apply grease to the splines and reinstall the univer· sel joint.

FINAL DRIVE GEAR / C ASE

RING GEAR REMOVAL

Remove the distance collar.

Remove the dust guard plate bolts. Remove the dust guard plate by turning it clockwise.

H ONDA

VTSOOC

Remove the eight case cover bolts and cover. If the ring gear stays in the cover, do the following:

Place the cover in a press with the ri ng gear down. Make sure the cover is securely supported.

Press the ring gear out of the cover with driver 07749-0010000 and anachment 07746-0010100 while holding the ri ng gear.

(1) CASE COVER

F INAL DR IVE

r::i!J\ HO NDA

VT500C

Remove the ring gear from the final drive case. Remove the O·ring guide by tapping it from the

opposite side.

R I NG G EAR BEAR IN G REMOV AL

Remove the ring gear bearing and gear adjusting spacer.

(1) R ING GEA R

(2)().R ING GUIDE

CASE COV E R OI L SEAL R EPLACEME NT

Remove the oil seal from the case cover and press in a new oil seal.

(11OI L SEAL

FINAL DRIVE

PINION GEAR REMOVAL

Set the pinion holder onto the pinion joint. Remove the pinion shaft nut.

Remove the tool and pinion jo-int.

Remove the retainer bolt lock tab.

Remove the pi nion retai n er with the pinion retainer wrench .

H O NDA

VT500C

(1) PINION HOLDER 07924-ME40000

(1IRETAINER

LOCK NUT WRENCH 07910-MA 10100

FINAL DRIVE

Ci/;\ H O NDA

VTSOOC

I nstall the pi nion holder plate onto the final gear case with the final gear case moun tin g nuts.

Screw in the pinion puller to the pinion shaft.

Remove the pinion by turning the pinion puller shaft.

PINION BEARING REMOVAL

Remove the O ring from the pinion shaft.

Pull the beari ng off the shaft with the bearing puller.

(t) PINION BEA R ING

(1) 0-R ING

)

(2) BEAR ING PU LLER

(COMME RCIALLY AVAI LABLE)

R emove the pinion adjustment spacer.

FINAL DR IVE

H O NDA

VT500C

PINION RETAINER OIL SEAL REPLACEMENT

Remove the 0-ring and oil seal from the pinion reteiner.

Drive a new oilseal into the retainer.

Coat a new 0-ring with oil and install it onto the

retainer.

IOOI L SEAL

(4)DR IVER 07749-0010000

(2) O-R ING(5)ATTACHMENT 07946-3330100

CASE BEAR I NG AND OI L SEAL

REPLACEMENT

Heat the gear case to 80°C (176°F). Tap the gear case with a plastic hammer and remove the ring gear and pinion bearings.

NOTE

The ring gear bearing may be removed using bearing remover. 30 mm 07936-8890100.

Remove the ring gear shaft oilseal.

Drive a new oil seal into the case, using the special tools.

(3) P NION RETAINER (4) 0RIVER 07749-0010000

(6) ATTACHMENT 07946-3710701 OR

07946-3710700

(2) DRIV ER

07749-0010000

(3) ATTACHl')IENT 07945-3330 100

FINAL DRIVE

H O NDA.

VTSOOC

Drive new pinion and ri ng gear b<!arin!JS i nto the case.

(1) DR IVER A

07749-0010000

(2) DR IVER A 07749--0010000

07746-0040700

BREATHER HOLE CLEANING

Remove the breather hole cap and blow through the breather hole with compressed air.

PINION GEAR ASSEMBLY

Install the original pinion gear $pacer.

NOTE

(1IPINION BEARING (2) PINION SPACER

FINAL DRIVE

H ONDA

VTSOOC

(1) DRIVER B

Press the bearing onto the pinion gear shaft with the tool as shown.

Install a new O·ring over the pi n ion shaft.

mo-RING

Place the pinion assembly in'to the gear housing. Drive the pinion assembly into the gear case until the pinion retainer threads can engage with the case threads.

Apply gear oil to the 0-ring and threads on the pinion retai ner.Install the 0-ring guide tool.

Screw in the pinion retai ner to press the pinion bearing in place, then tighten it to the specified torque.

TORQUE:100-120 N·m

(10-12 kg-m, 72-37 ft-lb)

(1) DRIVER C

07746-0030100

(2)RETAINER

LOCK NUT WRENCH 0791G-MA10100

(3) O·RING GUIDE 07973-4630200

RING GEAR ASSEMBLY

Install the original spacer onto the ring gear.

NOTE

(1)

RING GEAR SPACER ( RING GEAR BEARING

lfo . . - •

Place the ring gear bearing over the ring gear shaft.

Place a new ring gear bearing bn the ring gear shaft. Place the old bearing on top of it. Then, drive the new bearing onto the shaft with the old bearing and attachment. Then remove the old bearing.

Install a new O·ri ng onto the 0-ring guide.

Apply grease to the O-ring1 and drive the O·ring guide onto the ring gear shaft:.

COO.RING GUIDE \ll_O-RING

(31 DRIVER A

on49-0010000

(4) ATTACHMENT,32 x 40" mm 07746-0010200

Install the ring gear into the gear case cover.

Measure the clearanc:e between the ring gear and the ring gear stop pin with a feeler gauge.

CLEARANCE: 0.30-0.60 mm (0.012-0.024 inl

Remove the ring gear. If the clearance exceeds the service limit, heat the gear case cover to approxl· mately wJ; °c (176°F). Remove the stop pin by

turning the cover over and tapping it lightly with a plastic hammer.

CAUTION

Install a stop pin shim to obtain the correct clea r· ance.

SHIM THICK NESS: A: 0.10 mm (0.004 in)

B: O.15 mm (0.006 I n)

I nstall the shim and drive the stop pin into the case

Cover .

Clean all sealing material off the mating surfaces of the gear case and cover.

NOTE

Apply liquid sealant to the mating surface of the gear case cover.

GEAR TOOT H CONTACT PATTERN CHECK

Apply a thin coat of Prussian Blue to the pinion gear teeth for a gear tooth contact pattern check. Place the wave washer and ring gear into the gear case.

Apply gear oil to the lip of the oil seal on the gear case oover and install the gear case cover.

( 11 PR USSIAN B LUE (2) WAVE WASHER

Tighten the cover bolts in 2-3 steps un.ti l the cover evenly touches the gear case, then tighten the 8 mm bolts to the specified torque in a crisscross pattern in two or more stepS.

TORQUE: 23-28 N·m

(2.3-2 8 kg-m, 17-20 ft-lb) Then tighten the 10 mm bolts.

TORQUE: 40-50 N·m

(4.5-5.0 kg m, 33-36 ft-Ibl

Remove the oil filler cap from the final gear case.

Rotate ¢he ring gear several times in the normal direction of rotation. Check the gear tooth contact Pattern th rough the oil filler hole. The pattern is I nd icated by the Prussian Bl ue- applied to the pinion before assembly.

Contact is normal if the Prussian Blue is transferred to the approxi mate center of each tooth and slightly to the flank side.

IllNORMAL

(21HEE

- TOE - (21

- HEEL

(3)FACE I -

(4)FLANK

l6)DRIVE SIDE

l13) FACE COAST SIDE l4IFLANK

If the patterns are not correct, remove and replace the pinion spacer. Replace the pinion spacer with a

face.

thicker one if the contacts are too high, toward the

FINAL DRIVE

VT500C

Replace the pin ion spacer with a thin ner one if the contacts are too low, to the flank side. The patterns will shift about 1.5-2.0 mm (0.06-0.08 in) when the thickness of the spacer is changed by 0.10 mm (0.004 in).

PINIONSPACER:

A 1.32 mm (0.052 in)

B 1.38 mm (0.054 in)

C 1.44 mm (0.057 in)

D 1.50 mm (0.059 in)

E 1.56 mm (0.061 in)

F 1.62 mm (0.063In)

G 1.68 mm (0.066 in)

BACKLASH INSPECTION

Remove the oil filler cap.

Set the final gear assembly into a jig or stand to hold It stead y. Set a hori zontal type d ial indicator on the ring gear, through the oil filler hole.

Hold the pinion gear spline by hand. Rotate the ri ng gear by hand until gear slack is ta ken up. Turn the ri ng gear back and forth to read backlash.

STANDARD: 0.08-0.18 m m (0.003-0.007 in)

SERVICE LIMIT:0.30 mm (0.02 in)

Remove the dial indicator. Tum the ring gear 120° and measu re backlash . Repeat this procedure once more.

Compere the dif ferences of the three measurements.

DIFFERENCE OF MEASUREMENT SERVICE LIMIT:0.10 mm (0.004 in)

(1) TOO LOW

I I

(2)

(2/ FLANK (4i FLANK

(3) DRIVE SIDE COAST SIDE

If the difference in measurements exceeds the limit. it indicates that the bearing is not installed squarely. Inspect the bearings and reinstall if necessary .