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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.
VT500C (1) \ . (21 6 mm NUTS (3) 6 mm SH BOLTS
(1) VALVE ADJUSTER COVER
(21 BOLTS
CY LINDER/PISTON VTSOOC
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.
Remove the Cl-rings from the wate r pipes. Remove the cylinders.
Clean the top of each cylinder tJiorough ly with a gasket scraper.
NOTE
The gasket will come off easier if it is soaked in solvent. 111 GASKET
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)
NOTE SERVICE LIMIT:0.10 m m (0.004 in)
Place a shop towel into the crankse and remove the piston p in cl ips .
NOTE
Push the piston pin out and remove the piston.
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
SER VICE LIMIT: Top/Second : 011 lsld• rail):
0.50 mm (0.020 in) 1.10 mm (0.043 in)
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
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
Clean the piston domes, ring lands, and skirts.
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
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)
(4) SPACER (6) OIL R ING 11"",' - (5) SIDE RAIL
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.
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.
I nstall the gasket and dowel pins. H ONDA
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. ---'--'- ---'
NOTE
I nstall the gasket and dowel pi ns. Q\ H ONDA
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.
(:::J\ H O NDA
(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.
(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)
(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
20-25 N·m
(j "f4l'-----6 mm BOLT 8-12 N·m (0.8-1.2 kg·m,6-9 ft·lbl
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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