P500 Engine rebuild

[Pioneerpilot]

I’m getting started on the project of rebuilding the motor in my 2015 P500. I’ve been searching around for a free service manual, I have one for my P700 but no luck for the P5. The first issue I’m running in to is how to get the exhaust out I’ve already got all the under seat plastics and the back rack off so I was thinking if I can push it Forward enough I can swing it up out the top if the frame but it’s looking like I’ll have to remove the floorboard for that. Secondly, how the heck is the motor supposed to come out if the frame once it’s loose!?!? Does it slide to the back and out the top of the frame? Any input, links to video/write-ups fro, folks who have done this before would be greatly appreciate!

 

[Admin]

 

[JenElio]

I’m getting started on the project of rebuilding the motor in my 2015 P500. I’ve been searching around for a free service manual, I have one for my P700 but no luck for the P5. The first issue I’m running in to is how to get the exhaust out I’ve already got all the under seat plastics and the back rack off so I was thinking if I can push it Forward enough I can swing it up out the top if the frame but it’s looking like I’ll have to remove the floorboard for that. Secondly, how the heck is the motor supposed to come out if the frame once it’s loose!?!? Does it slide to the back and out the top of the frame? Any input, links to video/write-ups fro, folks who have done this before would be greatly appreciate!

Not sure on the 500 but if you upgrade your membership you have access to manuals and lots lots more info on here.

Also, @906UP is probly the man to ask questions on this project.

Good luck 👍

 

[Red500]

Welcome to the club from East Tennessee!
The 500 manual is there.
Pictures or it didn't happen.
Ohh. and red is the fastest.

 

[906UP]

I removed all the body work to give it a deep clean before pulling the engine then pulled it out the top, between the ROPS with a chain fall.

 

[906UP]

I tore mine down, split the cases, pulled everything out then milled the case "bore" to fit the 520 cylinder.

As @JenElio mentioned, a free download of the service manual is available on the site for contributing/lifetime members, I highly recommend it.

 

[Pioneerpilot]

How was your experience with the 520 kit? Was it worth it? I’ve seen kits available where the cylinder is machined so you don’t have to machine down the case, I would like to do it but it’s looking like that’s out of my budget for now. What did you do for fuel management?

 

[Pioneerpilot]

got the motor out just had to take the floor board out and remove the frame under the seat and was plenty of room to yank it out. About to drop off the cylinder to the machine shop and then starts the project of splitting the cases and cleaning out the motor. You can probably guess what caused this project to get started 🍻

 

[906UP]

How was your experience with the 520 kit? Was it worth it? I’ve seen kits available where the cylinder is machined so you don’t have to machine down the case, I would like to do it but it’s looking like that’s out of my budget for now. What did you do for fuel management?

Not worth the trouble, it might have a little more low end but not enough to notice. The ecu & injector is the same between the 500 & 520 so I didn't make any changes.

 

[HondaTech]

These can probably drop out the bottom like a 700. Never had one out though so im not 100% sure. The 700 can drop out with the engine subframe attached.

 

[Smitty335]

got the motor out just had to take the floor board out and remove the frame under the seat and was plenty of room to yank it out. About to drop off the cylinder to the machine shop and then starts the project of splitting the cases and cleaning out the motor. You can probably guess what caused this project to get started 🍻

View attachment 309972 View attachment 309973 View attachment 309974 View attachment 309975

Deep mud and water are your friend! HA!

 

[Red500]

My guess is that the "Send it" sticker on the fender was the cause.😁

 

[Morpheus]

Not sure on the 500 but if you upgrade your membership you have access to manuals and lots lots more info on here.

Also, @906UP is probly the man to ask questions on this project.

Good luck 👍

The 500 manual is available with a membership. Very cool to have that available.

 

[Montecresto]

I’m getting started on the project of rebuilding the motor in my 2015 P500. I’ve been searching around for a free service manual, I have one for my P700 but no luck for the P5. The first issue I’m running in to is how to get the exhaust out I’ve already got all the under seat plastics and the back rack off so I was thinking if I can push it Forward enough I can swing it up out the top if the frame but it’s looking like I’ll have to remove the floorboard for that. Secondly, how the heck is the motor supposed to come out if the frame once it’s loose!?!? Does it slide to the back and out the top of the frame? Any input, links to video/write-ups fro, folks who have done this before would be greatly appreciate!

Out of curiosity, why are you rebuilding the motor, did you have a failure of some sort…..🤔