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There's no way I would replace the vac valve with a manual on/off valve. First off are you even sure this is the real problem? It could be but it could also be several other things like leaking vacuum or clogged filter. Beside, wouldn't it be problematic for you to have a manual valve? Where would you mount it so it wouldn't be damaged and you could get to it when you need to without removing covers? Before my retirement I ran a large engineering group. One thing I learned is don't over engineer or even re-engineer something that normally works well. And the vac valve works fine under most situations. I'll bet you would forget to turn off a manual valve 60% of the time anyway. Bottom line is if the valve is bad just replace it but first be sure the valve is the problem. You can pickup a lot of used parts off of EBay if you want a cheaper way out.

Bob

I have an '06 V5 in my garage as well. To my knowledge there is nothing in the cooling system that will stop the motor from running even if it were over heating. From what you are saying there was no indication you were over heating just that your temp gauge is not working. But I am guessing this is unrelated to why the motor is shutting down. I am guessing you have ether a bad coil or a (oh crap I can't think of the name of the part). I think it's called a rectifier. In any case when they go bad they fail when hot. So the bike runs perfect for a while till the engine get hot then it shorts and the engine kills. Let it cool and it restarts and so on.

Here's a link to the V5 maintance manual also a like to a site with a lot of V5 owners.
www.alternativecruisers.com/index.php?action=tpmod;dl=item32
www.alternativecruisers.com/index.php?board=60.0

Good Luck,

Bob

EDIT: After you download the manual start looking at page #200 you may find some good info there. You should also consider the CDI as well. As I said above when certain electrical parts get hot they will open if falty. I am betting this is your problem. BTW, did you contact the place where you bought it? They should make the repair for you if you just bought it.

This isn't what I was talking about but I came across it in my listing. It does say it "remakes broken tabs". So it sounds simulare to what I was talking about.

Bob

www.partsforscooters.com/Small_plastic_repair_kit_172-16?sc=2&category=77182

There is also a product called 3M Scotch-Weld Epoxy Adhesive. You can Google it and fine the right type for your use.

In many cases if the screw is screwed directly into the plastic and the screw is just loose you can use a thread restore product. You just put the produce into the hole and insert the screw only 99% of the way. The following day tighten. Or I have used epoxy puddy. I've actually ground off the plastic area where the screw hole was and replaced it with a good quality plastic (2 part) epoxy puddy. After the puddy sets you can drill a hole smaller then the screw and then thread the screw back in. This puddy is available everywhere but remember we are not talking about body puddy like Bondo.

Bob

Yep, Bashan has it correct. Here's a link for a blow by blow fluid change on a V5. You can also download a complete V5 manual while your there. Just look under "downloads".

www.alternativecruisers.com/index.php?topic=19620.0

Bob

For the most part it's like a mail fuse. So it will act like the battery is dead. Pull the fuse and you will likely be able to see that it is bad. Use the spare fuse to replace it. Then buy a new fuse to replace the spare.

Bob

No you had it right the first time...It's a V5 and I own one.

Try asking your question here www.alternativecruisers.com/index.php?board=60.0

Could be only the overflow tube.

Bob