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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

 

l

t

(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)

2)
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 .

 

If backlash is too small, replace the ring gear spacer with a thinner one.

 

Backlash  is  changed  by  about  0.06-0.07  mm

(0.002-0.003 in) when thickness of the spacer Is

changed by 0.10 mm (0.004 i'n).

 

RING GEAR SPACER

A  1.32 mm (0.052 in)

B  1.38 mm (0.054 i n)

C 1.44 mm  (0.057 i n)

D 1.50 mm (0.059 i n) E 1.56 m m (0.061 i n) F 1.62 m m (0 063 in)

G  1.68 mm  (0.066 i n)

 

PINION JOINT INSTAL LATION

 

Install the appropriate pinion retai ner lock tab.

 

NOTE

 

J  There are two types of  lock tabs as shown.

 

 

Apply gea r oil to the oil seal lip contact surf ace of the pinion joi nt and install the pi nion join t.

 

I nstall the pi nion joint holder tool and tighten the pinion nut .

 

TORQUE:80-100 N m

(8-10 kg..m.58-72 ft lb) Remove the pinion joint holder tool.


 

 

(1) PINION HOLDER

07924-ME40000


 

 

FINAL DRIVE











HONDA.

VT S O OC


Make  sure  that  the gear assembly  rotates smoothly with out binding by turn ing the pinion joint.

 

 

I nstall the dust guard plate and tigh ten the bol t.


 

 

 

(1) DUST GUARD PLATE


 


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