![Honda CLYMER VF500C 500F (1984-1985) [102/350] Chapter four](/img/pdf.png)
Honda CLYMER VF500C 500F (1984-1985) [102/350] Chapter four
![Honda CLYMER VF500C 500F (1984-1985) [102/350] Chapter four](/views2/1121092/page102/bg66.png)
94
CHAPTER
FOUR
18. Make sure
the
seal
(Figure
137) on the
seal
plate
is
in
good
condition.
Replace
if necessary.
19.
Install the seal
plate
and
tighten
the screws
securely.
20.
Install the
following exterior
assemblies
onto
the
crankcase:
a. Cylinder
heads: this
chapter.
b.
Alternator: this
chapter.
c.
Countershaft
bearing
cover: this
chapter.
d.
Starter
clutch:
this chapter.
e.
External shift
mechanism:
Chapter
Five.
f.
Clutch:
Chapter
Five.
g.
Water
pump:
Chapter
Eight.
h. Starter
motor: Chapter
Seven.
i. Neutral switch:
Chapter
Seven.
j.
Coolant
pipes:
Chapter
Eight.
21.
Install
the
engine
as described
in this chapter.
22.
Flll
the
crankcase
with the
recommended
type
and
quantity
of engine
oil.
Refer to Chapter
Three.
23.
Fill
the
cooling
system
with
the
recommended
coolant.
Refer to
Chapter
Three.
PISTONS
AND
CONNECTING
RODS
The
engine
must
be
removed from
the
frame and
the crankcase disassembled
in order to
remove
the
pistons
and connecting
rods. The
pistons
and
connecting
rods are
removed
through
the top of
the
cylinder bore.
Piston
and Connecting
Rod
Removal/Installation
l.
Remove the engine as described
in
this chapter.
CAUTION
If
disassembling
a
well
run-in
engine,
inspect the
top of the cylinder
bores
for
a
ridge
where
the
piston
ring reaches
the top of its
travel
(Figure
138).
Perform
Step
2 only if there is
a
ridge
present.
2. If
there
is
a
ridge
at the
top of any
cylinder bore
the
ridge
must be
removed
with
an automotive
p
6mm bolt
and
washer
6
mm bolt
6
mm
bolts
Содержание
- Clylvteu 1
- Front cover 1
- Ffi ffi 2
- Chapter one 3
- Chapter three lubrication maintenance and tune up r r r r r 19 3
- Chapter two 3
- Contents 3
- Chapter eight ltqutd cooltng system r 206 4
- Chapter five clutch and transmission 113 4
- Chapter nine front suspension and steering r i r 219 4
- Chapter seven 4
- Chapter six fuel and exhaust systems 4
- Chapter ten 4
- Chapter eleven 5
- Chapter twelve 5
- Supplement 5
- Ffihlffil 43 4sl 6
- I t3l jllii u t0 tc kg cmz 142 99psi 6
- Ilfi tifr 6
- Ouick refereitce data 6
- Quick index 6
- Air pressure 7
- Ftw 23 8w 7
- I2v 60 55w 12v e 27w 7
- R2v as w 7
- Tl i1 1y1 3 4 liters 3 s u s qt 3 lmp qt 7
- Trne effflation pressure icoldi 7
- Up ro 200 ib 9s g front rear 7
- V 3 w iav 3w tzv 3w 7
- Chapter one 8
- General information 8
- Kk anv i ff 8
- Chapter one 9
- General information 10
- Chapter one 11
- General information 12
- Chapter one 13
- Trycr too rtccp 13
- Chapter one 15
- U w o b 15
- General information 16
- Chapter one 17
- General information 18
- General information 20
- Removing broken screws and bolts 20
- Chapter one 21
- General information 13 22
- Table r generat spegifigatioi s lcontinuedf 22
- T4 chapter one 23
- Chapter two 24
- Troubleshooting 24
- Chapter two 25
- Troubleshooting 26
- T8 chapter two 27
- And tune up 28
- Ih t i 1 28
- Lubrication maintenanc 28
- Lubrication maintenance tune up 28
- Chapter three 29
- Lubrication 30
- Maintenance and tune up 30
- Chapter three 31
- Lubrication maintenance and tune up 23 32
- Rhe un ofrf rn 3 must be 32
- Route h b r iy 7 fb o that it does 32
- Chapter thrbe 33
- Lubrication maintenance and tune up 34
- Chapter three 35
- Lubrication maintenance and tune up 27 36
- E chapter three 37
- Lubricatio maintenance and tune up 38
- Chapter three 39
- Lubricatio maintenance and tune up 40
- Chapter three 41
- Lubrication maintenance and tune up 33 42
- Chapter three 43
- Chapter nine and apply a lithium b il ffi 44
- Lubrication maintenance and tune up ts 44
- Chapter three 45
- Lubrication maintenance and tune up 37 46
- Chapter three 47
- Lubrication maintenance and tune up 39 48
- Chapter three 49
- Lubrication maintenance and tune up 50
- Chapter three 51
- Lubricatio maintenance and tune up 52
- Chapter three 53
- Lubrication maintenance and tune up 45 54
- Chapter three 55
- Spark plug condition 55
- Be sure yr lf ororut to the 57
- Chapter three 57
- Lubrication maintenance and tune up 58
- Chapter three 59
- Do not rr hryf f over more than absolutely n ecessary when spark plug leads are disconnected the electionlc 60
- Lubrication maintenance and tune up 60
- Chapter three 61
- Lubricatio maintenance and tune up 62
- Chapter three 63
- Lubrication maintenance and tune up 64
- Chapter three 65
- Chapter four 66
- Engine 66
- Ih t t 66
- Chapter four 67
- Stroke operatiig priiigipies 67
- Engine 68
- Chapter four 69
- Engine 70
- Chapter four 71
- Elilgil e mou t g hardware imagnai 71
- Engine mouilting hardware i terceptori 71
- Engine 72
- Chapter four 73
- Engine 65 74
- Chapter four 75
- Engine 76
- Chapter four 77
- T 1 n 1 t 77
- Engine 78
- Fl ffi 79
- I lt h l 79
- Engine 80
- Chapter four 81
- Chapter four 83
- Engine 84
- Engine 86
- Chapter four 87
- Engine 88
- Chapter four 89
- Engine 90
- Oil pump 90
- Chapter four 91
- Engine 92
- Chapter four 93
- Engine 94
- Alternator 95
- Chapter four 95
- Chapter four 96
- Engine 97
- Chapter four 98
- Engine 99
- Chapter four 100
- Engine 101
- Chapter four 102
- Chapter four 104
- Engine 105
- Chapter four 106
- As shown in figure 159 the important thing is that the ring gaps are not aligned with each other when installed 9 if new rings are installed measure the side clearance of each ring in its groove with a flat feeler gauge figure 155 and compare to dimensions listed in table l 108
- Chapter f our 108
- Connecting rod inspection 108
- Note before disassembly mark the rods and caps number them u1 n2 3 or 4 108
- Starting from the left hand side the left hand side referc to the engine sitting in the bike sframe not as it sits on your workbench 108
- Chapter four 110
- Chapter four 111
- Ii lll o 112
- To re clurch 112
- Chapter four 113
- Cover and 114
- Engine 114
- Ffiffi 114
- Specification 114
- Chapter four 115
- Engine 116
- Chapter four 117
- Engine 118
- Chapter f our 119
- Clu ich and transmission 120
- Clutch transmission 120
- G nr f 1 fl 120
- Int l il i 120
- Glutch 121
- Tt4 chapter five 121
- Clutqh and transmission 122
- Tl6 chapter five 123
- Chapter five 126
- Ci utch and transmission 127
- Chapter five 128
- Chapter fiye 130
- Clutch and transmission 131
- Clutch master cytinder 131
- Chapter ftye 132
- Clutch and transmission 133
- Chapter ftve 134
- Difficult 134
- Slave cylii der 134
- Clutch and transmission 135
- Chapter five 136
- Clutch and transmission 127 137
- Described in cnanlt t ll_ 137
- 3 21 4 5 138
- Chapter five 138
- External shift megi anisi i 138
- Clutch and transmission 139
- Chapter five 140
- Clutch and transmission 131 141
- Chapter five 142
- Clutch and transmission 143
- Clutch and transmission 145
- Chapter five 146
- Clutch and transmission 147
- Chapter five 148
- Clutch and transmission 139 149
- Chapter five 150
- Ii teriiial siiift meghanism 150
- Jjtr6l 150
- Clutch and transmission t4l 151
- Chapter five 152
- Clutch and transmission 153
- Chapter five 154
- Table 3 tral slullssloll spegificat oi s lcon nuedf 154
- Chapter six 155
- F ih t l 155
- Fuel and exhaust systems and emission controls 155
- Fuel exhaust system 155
- Suppl rrrsr own 155
- Xis uflidyhj 156
- Fuel exhaust and emission control systems 147 157
- Carburetor 158
- Chapter six 158
- O o o o 158
- Fu exhaust and emission control systems 159
- Chapter six 160
- Exhaust and_emtsston control systems 161
- Chapter six 162
- Fuel exhaust and emission control systems 153 163
- Chapter six 164
- Fuel exhaust and emission control systems 155 165
- Chapter six 166
- Fuel exhaust and emission control systems 157 167
- Chapter six 168
- S8 chapter six 169
- Euel exhaust and emission control systems 170
- Chapter six 171
- Fuel shutoff valve 171
- Exhaust and emission control systems 172
- Chapter six 173
- Fuel puiip al d fitter assembly iittergeptori 173
- Fuel pump al d filter assembly lmagilal 173
- Chapter six 175
- Fuel tank itnterceptori 175
- Crankcase breather system magnai 176
- Crankcase breather system u s only 176
- Fuel exhaust and emission control systems 165 176
- Chapter six 177
- Crankcase breather titterceptori 177
- Fresh j d 177
- Evaporatioi system 178
- Exhaust and emission control systems 178
- Chapter six 179
- Exhaust system mag ai 179
- Exhaust system tnterceptori 180
- Fuel exhaust and emission control systems 169 180
- Chapter six 181
- Carburetor model no main jet number carburetor no 1and3 rear no and4 front slow jet jet needle clip sefting float level ldle speed pilot screw initital opening 182
- Carburetor model no main jet number carburetor no 1and3 rear no and4 front slow jet jet needle clip setting float level ldle speed pilot screw initital opening 2 full turns out 182
- Fuel exhaust and emission control systems 171 182
- Interceptor 49 state models 182
- No 102 no 105 no 38 non adjustable 6 mm 0 4 in 1 300 100 rpm 182
- Pilot screw initial opening 2 full turns out 182
- Chapter seven 183
- Electrical system 183
- Ffiiilftu 183
- Electrical system 190
- Chapter seven 191
- Electrical system 192
- Chapter seven 193
- Electrical system 194
- Chapter seven 195
- Electrical system 196
- Tteadltght assembly magl al 196
- Adjust scre 198
- Electrical system 198
- Seat as described in chapter 198
- F hl fi 199
- Y b o l i i 200
- Chapter seven 201
- Electrical system 202
- Chapter seven 203
- Electrical system 204
- Chapter seven 205
- Electrical system 206
- Caution after the instrument cluster has been removed set the cluster down with the meter face and needles facing upward if the cluster is set with the faces down the needle damping fluid will leak out onto the instrument face and lens 207
- Chapter seven 207
- Install by reversing these removal steps 8 make sure all electrical connectors are tight and free of corrosion 207
- Instrument cluster removal installation 207
- Remove the nuts securing the instrument cluster to the upper fork bridge remove the instrument cluster 207
- Electrical system 208
- Chapter seven 209
- Fuel reserve sensor testing replacement magna 209
- Note the fuel tank must contain less than 3 liters 0 3 u s gal offuel in order to perform this test 209
- Electrical system 210
- Chapter seven 211
- Chapter seven 213
- Electrical system 214
- Fuse holder imag ai 214
- Tables are on the following pages 214
- 0 0 0 0 0 215
- Chapter seven 215
- Starter runs continuously 215
- Starter turns does not turn engrne 215
- Table 2 replacement bulbs 215
- V 2318w 12v 23 w 12v 3 w 12v 3w 12v 3w 215
- V 60 55w 12v 8127w 215
- Wattage 215
- Wire golor 215
- X x x x x 215
- Electrical system 216
- X x x x x 216
- Chapter eight 217
- Liquid cooling system 217
- S il rw 217
- Liouid cooling system 207 218
- Radtator assembly imagnai 218
- 30 28 3l 219
- Appearance there is coolant in the oil system if so correct the cooling system problem immediately 219
- Caution after the cooling system is corrected drain and thoroughly flush out the engine oil system to eliminate all coolant residue refill withfresh engine oil refer to chapter three 219
- Chapter eight 219
- If the cooling system requires repeated refilling there is probably a leak somewhere in the system 219
- Pressure check 219
- Radtator assembly ilterceptori 219
- D cooling system 222
- Chapter eight 223
- Liquid cooling system 224
- Chapter eight 225
- Pull the battery box partially out of 225
- The battery as described in chapter 225
- Liquid cooling system 226
- Water pump assembly 226
- Chapter eight 227
- Liquid cooling system 228
- Chapter eight 229
- Coolant pipes and hoses 229
- Refer to figure 3 magna or figure 4 interceptor whenever any of the coolant pipes and fittings are removed for service procedures the o ring seals figure 32 should be inspected and replaced as necessary o ring seals tend to harden after prolonged use and exposure to heat and therefore lose their abality to seal properly 229
- Table 2 sub frame toroue specifigations 229
- Whenever any component of the cooling system is removed inspect the hose s and determine if replacement is necessary 229
- Chapter nine 230
- Front suspension 230
- Front suspension and steering 230
- I ir rk 230
- Chapter nine 231
- Front suspension and steering 22t 232
- Chapter nine 235
- Front suspension and steering 236
- Chapter nine 237
- Front suspension and steering 238
- Chapter nine 239
- Ffi j l7 9 239
- L2 e l3 239
- Chapter nine 241
- Front suspension and steering 242
- Chapter nine 243
- Front suspension and steering 244
- Chapter nine 245
- Front suspension and steering 246
- Chapter nine 247
- 9l f ffi gl f 248
- Froirr fork magnai 248
- Froi t fork right hand side tnterceptori 249
- Fiis ii 250
- Fro it fork left hai d side 250
- Front suspension and steering 250
- Chapter nine 251
- Front suspension and steering 252
- Chapter nine 253
- Front suspension and steering 254
- Chapter nine 255
- Front suspension and steering 256
- Chapter nine 257
- Chapter nine 259
- After the assembly is complete push on the piston b figure 95 and make sure it moves freely turn the adjustment knob to all 4 settings make sure it moves freely 260
- Clean all parts in solvent and dry thoroughly with compressed air 2 inspect the piston return spring and the check ball spring for wear or damage 3 inspect the piston o ring seal in the case figure 98 and the oil control orifice for wear or deterioration replace if necessary 4 inspect the flat seal on the fork leg figure 99 for wear or deterioration replace if necessary 5 inspect the piston boot figure 100 and all rubber parts figure 101 for wear or deterioration replace if necessary 6 inspect the piston and piston collar figure 102 for scratches and wear replace as necessary 7 make sure the oil flow holes in the oil control orifice and the case are clean and unobstructed blow out with compressed air do not use a piece of wire as it may gouge the interior surface and disrupt the flow path 8 inspect the o ring seal on the case figure 103 for wear or deterioration replace if necessary 260
- Front suspension and steering 249 260
- I fif i t ffi 260
- Inspection 260
- Air pressure magna 261
- Chapter nine 261
- Do not position the adjuster between the numbered detent adjustment points 261
- Psi 2 0 kg s6z 32 psi 2 5 kgls111z 1 261
- Psi 2 0 kg smz 28 psi 2 0 kg srnz 261
- Psi 2 5 kgl661z 1 32 psi 2 5 kgls11lz 1 261
- Psi 2 kg cmz 40 psi 2 kg s6z 261
- Recommended air pressure for factory equipped tires altermarket tires may require different air pressure maximum load limit includes total weight of motorcycle with accessories rider s and luggage 261
- Table 2 tire lnftatlol pbessure lcotdl 261
- Up ro 200 lb 90 kg front rear maximum load limit front rear 261
- Chapter ten 262
- Rear suspension 262
- Chapter ten 263
- Rear suspension 264
- Chapter ten 265
- Disassembly in this 265
- Hand make sure the 265
- Rear suspension 266
- Rear wheel a d hub magnai 266
- Rear wheet and i ub tntergeptori 266
- Chapter ten 267
- Rear suspension 257 268
- Chapter ten 269
- Rear shock absorber dual si ocki 270
- Rear suspension 270
- Chapter ten 271
- Align the upper spring seat to the upper joint when releasing the spring compressor tool 272
- Note after the locknut ls tightened completely the locknut must be against the bottom surfoce of the upper ioint and against the end of the threads on the damper rod 272
- Rear suspension 272
- Chapter ten 273
- Rear shock absorber srl gle shocki 273
- Rear suspension 274
- Chapter ten 275
- Shock absorber linkage 275
- Rear suspension 276
- Chapter ten 279
- As described in this 280
- Described in chapter 280
- Rear suspension 280
- Chapter ten 281
- Rear suspension 282
- Brakes 283
- Chapter eleven 283
- Ry ry wr 284
- Chapter eleven 285
- Front caliper itnterceptori 285
- Brakes 286
- Chapter eleven 287
- Bed the pads in gradually for the first 80 km 50 miles by using only light pressure as much as 288
- Brakes 288
- D tighten the axle holder s front nut first and then the rear to the torque specification listed in table 2 e recheck the clearance again readjust if necessary 288
- Warning do not ride the motorcycle until you are sure the bral es are operating coruectly with full hydraulic advantage if necessary bleed the bralce as described in this chapter 288
- Chapter eleven 289
- Brakes 279 290
- Caution do not spill any bral e fluid on the painted portion of the front wheel or front fork slider wash off any spilled bral e fluid immediately as it will destroy the finish use soapy water and rinse complaely 290
- Front caliper 290
- Refer to figure 2 magna or figure interceptor for this procedure 290
- Removal 290
- Chapter eleven 291
- Brakes 292
- Rearcaltper tnterceptori 292
- Chapter eleven 293
- Brakes 283 294
- Chapter eleven 295
- Rear master gylinder 295
- Brakes 296
- In the ffi 296
- Chapter eleven 297
- Brakes 298
- Chapter eleven 299
- Brakes 300
- Chapter eleven 301
- Brakes 302
- Chapter eleven 303
- Brakes 293 304
- Rear brake pedal imagnai 304
- Chapter eleven 305
- Rear brake pedal tnterceptori 305
- Chapter eleyen 307
- Brakes 308
- 1 2 10 14 25 30 20 25 30 40 35 40 18 25 18 25 24 30 309
- Brake hose union bolts front master cylinder cover screws master cylinder clamping bolt caliper pivot bolt caliper mounting bolt caliper bracket mounting bolts brake disc mounting bolts front axle holder nuts rear brake torque link brake arm bolt 309
- Chapter eleven 309
- Table 2 brake toroue specifigations 309
- Chapter twelve 310
- Frame and body 310
- Frame body 310
- Chapter twelve 311
- Froilt farrrlrg r terceptori 311
- Frame and body 301 312
- Chapter twelve 313
- Seat al d rear cowl lmacital 313
- Disconnect the electrical connectors from both rear turn signal assemblies 6 remove the bolts securing both turn signal assemblies and remove both assemblies 7 remove the bolts securing the gnp rail on each side and remove both grip rails 8 remove the flange bolts securing the taillight bracket and remove the taillight bracket and taillight assembly 9 remove the bolts securing the rear section of the rear fender 10 from underneath the rear fender hold onto the bolt plate assembly and remove the nut securing the front and rear section of the rear fender to the frame bracket remove the bolt plate assembly 314
- Frame and body 303 314
- Seat al d rear cowl itnterceptori 314
- Chapter twelve 315
- Rear feitder magtal 315
- Frame and body 305 316
- Rear feilder tnterceptori 316
- Chapter twelve 317
- 1986 service information 318
- Service information 318
- Supplement 318
- Chapter one 319
- General informa tion 319
- Supplement 319
- Chapter three 320
- Engine ol and fnter change lx ff ttiilx 3 fij ti li n n preated 320
- Lubrication maintenance and tune up 320
- Service information 320
- Supplement 321
- Supplement 323
- Service information 324
- Supplement 325
- Chapter four 326
- Engine 326
- Service information 326
- Supplement 327
- Service information 328
- Supptbment 329
- Service information 330
- Supplement 331
- Service information 321 332
- A mm botts o 6 mm botts 333
- Supplement 333
- Service information 323 334
- Supplement 335
- Service information 336
- 0 591 0 588 0 589 0 587 0 588 0 586 0 587 0 585 586 337
- Blue black brown green yellow 337
- Letter a 35 00 35 08 mm yeilow 1 780 1 783 in 337
- Letter b 35 08 35 16 mm green 1 783 1 786 in 337
- Number 1 32 10 32 02 mm 1 60 1 599 in 337
- Number 2 31 94 32 02 mm 1 596 1 599 in 337
- Table 6 col egflilc rod bear i g setecttoti 337
- Table 7 coill ecrll c rod beabtng tsert thtckness 337
- Table 8 llallr jour ai beantilc select o main journal od size code letter and dimension 337
- Chapter five 338
- Chapter six 338
- Clutch and transmission 338
- Fuel and exhaust systems and emission controls 338
- Service information 338
- E supplement 339
- Service information 329 340
- Chapter eight 341
- Chapter seven 341
- Cooling system 341
- Electrical system 341
- Supplement 341
- 30 28 3l 342
- Service information 331 342
- Chapter nine 343
- Chapter ten 343
- Front suspension and steering 343
- Rear suspension 343
- Supplement 343
- Iitidex 344
- N3 r14 344
- Quick index 344
- 177 178 t79 177 178 179 181 196 r97 r39 r42 345
- 22s 264 266 345
- 231 200 20r 345
- 24r 242 345
- 269 266 267 267 269 345
- 33 l 213 214 214 2t7 345
- 330 r27 r32 r29 r30 r30 r32 345
- 39 39 40 2 r 4 2t2 213 206 208 217 208 209 209 212 345
- Hubs front 345
- L6r r62 r98 199 345
- R05 l 08 345
- R66 r70 345
- T3 2r4 157 158 346
- Wiring diagrams 348
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