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CLYMER VF500C 500F (1984-1985)
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Honda CLYMER VF500C 500F (1984-1985) [20/350] General information

GENERAL

INFORMATION

REMOVING BROKEN SCREWS AND

BOLTS

1. Center

punch

broken stud

Remove

broken stud

2. Drill hole in stud

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

Honda CLYMER VF500C 500F (1984-1985) [20/350] General information

Содержание

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