Remove t ht 1t1 rte r motor case rews .

Inspect the brushes and measure the brush  length. Measure brush spring tension with a spring scale.

SERVICE LIMITS:

Brush  length:          6.5 mm (0.26 in>

Brush spring tension: 545 g (19.2 oz>

 

COMMUTATOR  INSPECTION

 

Remove the starter motor case.

 

 

(2) BRUSH

LENGTH

(1IBRUSH SPRING

 

 

 

IllCOMMUTATOR

 

Inspect the commutator bars for discoloration. Bars discolored in pairs indicate grounded armature coils.

 

NOTE

 

Check for contin uiw between pai rs of commutator bars. Also, make  a  resistance check  between  in· d lvidual  commu tator bars and the armature shaft. There should be no continuity.

 

 

(1ICONTINUITY BETWEEN COMMUTATOR BAR PAIRS: NORMAL

 

(2) NO CONTINUITY BETWEEN

COMMUTATOR BARS AND ARMATURE SHAFT:NORMAL

 

 

ASSEMB LY/INSTALLATION

 

Assemble the starter  motor. Align the case notch with the brush holder pin.

 

 

Install the rear cover aligning its slot with the brush holder pin.

 

Install the starter  motor in the reverse order of removal

 

Connect the water pipe.

Refill the radiator with coolant (page 6-4). Install the right rear muffler.

 

 

STARTER RELAY SWITCH

INSPECTION

 

Depress the starter switch button with the ignition ON. The coilis normal if the starter relay switch clicks.

 

Connect an ohmmeter to tlhe starter relay switch terminals.

 

Connect a 12 V battery to the switch cable termi­ nals.

 

The switch is normal if thereis continuity.

(1) BRUSH HOLDER (2)NOTCH (3) PIN               (4) CASE

 

 

 

(11 PIN (2) BRUSH HOLDER   (3) SLOT

 

(4) REAR BRACKET

 

 

ELECTR IC STARTER

VT500C

CLUT C H DIODE

REMOVA L

 

Remove the fuel tank.

 

Remove the clutch diode from the wire harness.

 

INSPECTION

 

Check for continuiw with an ohmmeter .

(1) IN ONE DIRECTION: CONTINUITY

(2) IN THE REVERSE DIRECTJ9N:NO CONTINUITY

 

 

SWITCHES

 

OIL PRESSURE SWITCH

Drain the engine oi l.

 

Disconnect the oil pressure switch lead and remove the switch.

 

Check for continuity while applyi ng pressure to the switch.

 

Replace the switch ii neces.sa ry.

 

Apply a liquid sealant to the switch threads before installing the switch .

Screw  the  switch  i n  the  crankcase  and  leave  two

th reads  from  the  bottom.  Then  tighten  it  to the sPecified torque.

TORQUE :10-14 N·m

(1.0-1.4 kg-m, 7-10 ft·lb)

fA\ H O NDA

VT500C

111 CONTINUITY : BELOW 2.8 psi

 

 

NO CONTINUITY :ABOVE 2.8-5.6 psi

CAUTIOM

 

BRAKE LIGHT SWITCH

Be  sure  the  rear  brake  light  switch  is  properly adjusted (page 3-15).

 

Then  check  the rear bra ke  light  switch  for con­ tinuity with the rear brake applied.

 

Check  the  front brake light switch for continuity with the front brake applied .

 

Replace either switch i f there is no contin uity when the correspondi ng brake is applied.

 

NEUTRAL / DD SWITCHES

Remove  the  seat  and  fuel tank  and disconnect the neu tralfOD switch  connector.

Check  the  continuity  of  the  switches  with  the

transmission i n each gear position .

 

 

\Color		Lg/A	G/O
P osition	'\
1st
N		c
2nd
3rd
4th
5th OD			er-	-

 

 

R EMOVA L

 

Shift the transmission into neutral.

Remove the left crankcase rear cover and gear shift linkage.

 

Remove the mounting bolts and switch.

 

INSTALLATI ON

 

Position the switch rotor pin as shown and install the switch by aligning the pin with the groove of the gear shift drum.

 

 

 

 

CLUTCH SWITCH

Disconnect the wire leads from the clutch switch.

 

Check the continuity of the cl utch lever (saf ety) switch with the clutch released and applied. Replace if necessa ry.

 

LEVER APPLIED: CONTllllUITY

LEVER NOT APPLIED: NO CONTINUITY

HANDLEBAR SWITCHES

The  handlebar  cluster switches  (ligh ts , turn signals. horn, etc.) must be replaced as assemblies.   •

 

Remove the headlight and headligh t case.

 

Continuity tests for the components of the handle· bar cluster switches follow:

 

Continuity  should  exist  between  the color coded wires in each chart.

 

 

HEADLIGHT  HI-LOW SW ITC H

(!) HEADLIGHT

HI-LO SWITCH

 

(21HOR N BUTTON     (31TURN SIGNAL SWITCH

 

Headlight Hi-Low Switch

 

HI:

MIDDL E (N): LO:

B/W to B

B/W to W to B B/W to W

 

TURN SIGNAL SWITCH

 

LEFT:      Gr to 0

Turn Signal Switch

 

R        L

R IGHT: Gr to LB

 

 

HOR N BUTTON

 

LG to W I G with button depressed ; continuity. No continuity with button released.

 

 

Horn Button

0           (-")

v-

 

 

 

 

 

STARTER BUTTON

 

Bk to Y/R with button pushed in; continuity. Bk to Y/R with button out; no continuity.

 

Starter Button

 

BAT2 ST FR EE       PUSH

u-    u-

 

 

ENGINE STOP SWITCH

RUN: Bk to Bk/W; continuity. OFF:       No continuity.

 

BAT2 IG OFF     RUN 0 0 OFF

Engine Stop Switch

LIGHTING SWITCH

OF F: No continuity

P : Br/B to BrN/; continuity

HL : Br/B to BrNI. BNI to Bk/R; continuity

 

 

IGNITI ON SWITCH

Remove the headlight, headlight case and instru­ ment lower cover and disconnect the ignition switch coupler.

 

Check continuitV of terminals on the ign ition switch coupler  in each switch position.

 

SWITCH POSIT ION

.-...

BAT4 TL H L BAT5 OFF         p     -'           H         .......   .......

-.

 

LOCK : OFF: ON: PAR K:

No, continuity. No continuity.

R to Bk, BrNI to Br;continuity. Br to R;continuity.

 

\Terminal   BAT   IG   TL1   TL2   p Pos i t i on  \ ON     0-L                 OFF           p 0                 LOCK

u-    {-)

n-

 

(-)

 

SWITCHES

VTSOOC

THERMO S TATIC SWIT C H

The cooling fan motor is actuated by the thermo­ static switch loMt•rl in the left tank of the radia tor.

 

Run the engine until coolarlt temperature reaches 80-102°C (176-216°F) . The fan motor should start running. The fan motor should stop when the coolant temperature drops to 93-97°C (200- 2070F).

 

If the fan motor does not  start, discon nect  the B/L and G leads from the thermostatic switch and short them together with a jumper wire as shown.

 

Turn the igni tion switch on. The cooli ng fan motor should start running. If it s-tarts, replace the fan thermostatic switch and retest.  ·

 

If it does not start, check for battery voltage from the B lead (positive)  to  the  B/L lead (negative) of the fan motor coupler. If there is no voltage, check for a blown or faulty fuse, loose terminals or connectors, or an open circuit.

 

 

TEMPERATURE  SENSOR

Remove the f uel tank .

Disconnect the G/B wire from the temperature sensor.

 

(l) THERMOSTATIC SWITCH  LEADS (2) JUMPER

WIRE

 

 

With the engine cold, use an ohmmeter to measure resistance between the tem perature sensor terminal and the engine.

 

Check the temperature of the coolant.

 

 

Run the engine and measure the change i n resistance of the sensor with the coolant at the temperatures shown in the chart,

 

 

Temperature 00°c (140,.F) 85°C (185°F ) 110°c (230°F) 120°c (248° F) Resistance (Ohms) 104.0 43.9 20.3

16.1

 

 

Replace  the  sensor  if  it  i·s  out of  specifications by more than 10% at any temperature listed.

 

TEMPER A T URE GAUG E

Remove the fuel ta nk.

Disconnect  the  wi re from  the temperatu re sensor and short it to ground.

 

Turn  the  ignition switch  to ON. The temperatu re gauge needle should move a II the way to the right.

 

CAU TIO N

(1) TEMPERATU RE GAUGE

 

(2) TEMPERATU R E SENSOR

 

 

SWITCHES

 

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