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CLYMER VF500C 500F (1984-1985)
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Honda CLYMER VF500C 500F (1984-1985) [130/350] Chapter fiye

Honda CLYMER VF500C 500F (1984-1985) [130/350] Chapter fiye

122 CHAPTER

FIYE

3.

Check both the

primary

and secondary

cup

for

damage,

Replace as

necessary.

Replace

the

piston

if

the

secondary cup

requires replacement.

4.

Check

the

hand lever

pivot

bore

in

the clutch

master

cylinder.

If

worn

or elongated, the

master

cylinder

must be

replaced.

5.

Inspect

the

pivot

bore in the

hand lever.

If worn

or elongated

it must

be

replaced.

6.

Make sure the

passages

in

the bottom

of the

fluid

reservoir are clear. Check the

reservoir cap

and

diaphragm

for damage and deterioration

and

replace as

necessary.

7. Inspect the condition

of the threads

in the bore

for the fluid

line.

8.

Measure the cylinder bore

(Figure

36).

Replace

the clutch

master cylinder

if

the bore exceeds

the

specifications

given

in Table 2.

9.

Measure

the

outside diameter of the

piston

as

shown

in Figure 37

with

a

micrometer.

Replace

the

piston

assembly

if

its

diameter

is less than the

specifications

given

in Table 2.

Assembly

l. Soak the

new

cups in

ft

rh

hydraulic

fluid for

at

least

15 minutes to

make

them

pliable.

Coat

the

inside of the cylinder

with fresh fluid before

assembling

parts.

CAUTION

When

installing

the

piston

assembly,

do

not allow the

cups to turn inside out,

as

they

will

be damaged

and allow

clutch

fluid

leakage

within

the

cylinder

bore.

2.

Install the spring,

primary

cup and

piston

assembly

into the cylinder together.

NOTE

Be

sure to install

the

primary

cup

with

the

open end in

first,

toward the

spring.

3.

Install the circlip;

make

sure

it seats

firmly in

the

groove.

4. Slide

in

the

rubber

boot,

the

pushrod

and the

pushrod

end

piece.

5.

Install the diaphragm and

cover.

Do not

tighten

the

cover screws

at this time as

fluid will have to be

added

later.

6.

Install

the

lever

onto

the master cylinder body.

7.

If removed, install the clutch switch.

8.

Install

the clutch

master

cylinder and

bleed the

clutch

system as

described

in

this chapter.

Clutch

Hose Replacement

There is no

factory-recommended replacement

interval

but

it is

a

good

idea to replace the clutch

hoses

every

four

years

or

when

they show signs of

cracking or

damage.

The hydraulic

hose assembly

consists of

2 flexible

hoses and

I

section of

metal

tubing.

Refer

to

Figure 35

for this

procedure.

CAUTION

Cover the

front

wheel,

fender,

(front

fairing

on

models

so equipped)

and

frame

with

a

heavy

cloth or

plastic

tarp

to

protect

them

from

accidental

spilling

of

hydraulic

fluid.

Wash

the

fluid

off

of

any

painted

or

plated

surface

immediately,

as it

will

destroy

the

finish.

Use

soapy

water

and

rinse

completely.

l. Remove the seat

(Chapter

Twelve) and both

side.

2.

On

Interceptor

models,

remove the

front

fairing

as described

in

Chapter

Twelve.

3.

Remove the

fuel

tank as

described

in

Chapter

Six.

4. Drain

the

fluid from the

entire system

as

follows:

a.

Attach

a

hose to the

bleed

valve

(Figure

38)

on the clutch

slave

cylinder.

b.

Place

the

loose end

into a container

and

open

the bleed

valve.

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