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Honda NSS250A Reflex 2001-2007, Manual

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HYDRAULIC BRAKE

17-18

Remove the brake hose oil bolt, sealing washers
and brake hose eyelet.

Remove the master cylinder holder bolts, holder
and master cylinder.

DISASSEMBLY

Remove the pivot nut, pivot bolt and brake lever.

Remove the screw and brake light switch.

BRAKE HOSE

OIL BOLT

SEALING WASHERS

BOLTS

HOLDER

MASTER CYLINDER

PIVOT BOLT

BRAKE LEVER

PIVOT NUT

SCREW

BRAKE LIGHT SWITCH

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Summary of Contents for NSS250A Reflex 2001-2007

Page 1: ...l model CODE AREA TYPE ED EUROPEAN DIRECT SALES Austria Belgium Bulgaria Croatia Czech Denmark Finland Germany Greece Holland Hungary Iceland Israel Italy Latvia Luxembourg Macedonia Norway Poland Por...

Page 2: ...nt When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and the skills...

Page 3: ...e signal words mean You WILL be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be KILLED or SERIOUSLY HURT if you don t follow instructions You CAN be HURT if you don t follow instr...

Page 4: ...isulfide grease containing more than 3 molybdenum disulfide NLGI 2 or equivalent Example Molykote BR 2 plus manufactured by Dow Corning U S A Multi purpose M 2 manufactured by Mitsubishi Oil Japan Use...

Page 5: ...UTCH SPECIFICATIONS 1 9 CRANKCASE CRANKSHAFT BALANCER SPECIFICATIONS 1 9 FRONT WHEEL SUSPENSION STEERING SPECIFICATIONS 1 10 REAR WHEEL PARKING BRAKE SUSPENSION SPECIFICATIONS 1 10 HYDRAULIC BRAKE SPE...

Page 6: ...te all electrical wires as shown in the Cable and Harness Routing page 1 21 9 Do not bend or twist control cables Damaged control cables will not operate smoothly and may stick or bend ABBREVIATION Th...

Page 7: ...L IDENTIFICATION The frame serial number is stamped on the right side of the frame The engine serial number is stamped on the left side of the crankcase FRAME SERIAL NUMBER ENGINE SERIAL NUMBER NSS250...

Page 8: ...number is stamped on the lower side of the throttle body LABEL The color label is attached as shown When ordering color coded parts always specify the designated color code THROTTLE BODY IDENTIFICATI...

Page 9: ...Trail length 92 mm 3 6 in Fuel tank capacity 12 liter 3 2 US gal 2 6 Imp gal ENGINE Bore and stroke 68 0 x 68 6 mm 2 68 x 2 70 in Displacement 249 cm3 15 2 cu in Compression ratio 10 2 1 Valve train...

Page 10: ...n Fuel tank capacity 12 liter 3 2 US gal 2 6 Imp gal ENGINE Bore and stroke 68 0 x 68 6 mm 2 68 x 2 70 in Displacement 249 cm3 15 2 cu in Compression ratio 10 2 1 Valve train Chain drive and OHC Intak...

Page 11: ...006 0 009 0 35 0 014 Side clearance 0 02 0 09 0 001 0 004 0 12 0 005 ITEM SPECIFICATIONS Throttle body identification number GQBAA Idle speed 1 500 100 min 1 rpm Throttle grip freeplay 2 6 mm 1 16 1 4...

Page 12: ...8 0 0019 0 09 0 004 Valve guide projection above cylinder head IN 11 2 11 5 0 44 0 45 EX 12 2 12 5 0 48 0 49 Valve seat width IN EX 0 90 1 10 0 035 0 043 1 5 0 06 Valve spring free length IN EX 37 09...

Page 13: ...5 33 Shoe lining thickness 4 0 0 16 1 5 0 06 ITEM SPECIFICATIONS Final reduc tion oil capac ity After draining 0 28 liter 0 30 US qt 0 25 Imp qt After disassembly 0 30 liter 0 32 US qt 0 26 Imp qt Rec...

Page 14: ...ght 70 g 2 5 oz maximum Parking brake Drum I D 95 0 95 2 3 74 3 75 95 5 3 76 Lining thickness 2 8 3 0 0 11 0 12 2 0 0 08 ITEM STANDARD SERVICE LIMIT Front Specified brake fluid DOT 4 Brake disc thickn...

Page 15: ...k 10 BTDC at idle ITEM STANDARD SERVICE LIMIT Starter motor brush length 12 0 0 47 6 5 0 26 ITEM SPECIFICATIONS Bulb Headlight High Right 12 V 55 W Low Left 12 V 55 W Position light 12 V 5 W x 2 Brake...

Page 16: ...TION 1 12 Honda S Matic System SPECIFICATIONS NSS250A Unit mm in ITEM STANDARD SERVICE LIMIT Movable drive face position sensor resistance 0 6 0 k Driven pulley sensor peak voltage 0 7 V minimum maxis...

Page 17: ...0 0 1 0 7 Left outer rail screw 4 4 1 0 0 1 0 7 Seat hinge cover screw 4 5 1 6 0 2 1 2 Seat hinge nut 3 6 10 1 0 7 Damper stay bolt 2 6 10 1 0 7 Tail cap cover stay bolt washer 2 6 10 1 0 7 Tail cap...

Page 18: ...ot band screw 2 4 1 0 0 1 0 7 Bank angle sensor mounting screw 2 4 1 2 0 1 0 9 Fuel tank bolt 4 8 22 2 2 16 ALOC bolt replace with a new one Fuel pump unit mounting nut 5 6 12 1 2 9 See page 6 78 ITEM...

Page 19: ...locking agent to the threads ITEM Q TY THREAD TORQUE REMARKS DIA mm N m kgf m lbf ft Right Left crankcase socket bolt 2 8 23 2 3 17 Apply locking agent to the threads Cam chain tensioner bolt 1 6 12 1...

Page 20: ...luid to the threads Brake hose oil bolt 7 10 34 3 5 25 Brake light Inhibitor switch screw 2 4 1 2 0 1 0 9 Brake light switch screw 2 4 1 2 0 1 0 9 Brake lever pivot nut 2 6 6 0 6 4 4 Brake lever pivot...

Page 21: ...4 1 2 0 1 0 9 Parking brake light switch screw 1 3 1 47 0 1 1 1 Front turn signal light switch screw 4 4 1 0 0 1 0 7 Headlight screw 16 5 1 1 0 1 0 8 License light nut 2 5 1 5 0 2 1 1 U nut Rear combi...

Page 22: ...sur face Each O ring whole surface Each ball bearing and needle bearing rolling area Each rolling area and sliding surface Multi purpose grease Driven face guide groove guide pin Fill up 4 0 5 0 g 0 1...

Page 23: ...0 mm 0 08 0 12 in Oil filter boss threads engine side Cam stopper plate bolt threads Coating width 6 5 1 0 mm 0 26 0 04 in from the tip of exclude 2 0 3 0 mm 0 08 0 12 in Cam sprocket bolt threads Co...

Page 24: ...n ring whole surface Silicone grease Caliper dust seal whole surface Console box lock cable inner surface Fill up 0 20 g 0 007 oz mini mum Seat lock cable inner surface Fill up 0 20 g 0 007 oz mini mu...

Page 25: ...ay CONNECTOR RIGHT TURN SIGNAL POSITION HEADLIGHT 4P Blue CONNECTOR LEFT TURN SIGNAL LIGHT 3P Black CONNECTOR RIGHT TURN SIGNAL LIGHT 3P Natural CONNECTOR LEFT HEADLIGHT 3P Black CONNECTOR RIGHT HEADL...

Page 26: ...E INHIBITOR SWITCH WIRE TURN SIGNAL RELAY TURN SIGNAL RELAY CONNECTOR BANK ANGLE SENSOR 3P Black CONNECTOR INSIDE BOOT CONNECTORS RIGHT HANDLEBAR SWITCH 8P Green CONNECTOR IGNITION SWITCH 2P Gray CONN...

Page 27: ...12P Black CONNECTOR BANK ANGLE SENSOR WIRE INSIDE BOOT CONNECTORS RIGHT TURN SIGNAL POSITION HEADLIGHT 4P Blue CONNECTOR LEFT TURN SIGNAL POSITION HEADLIGHT 4P Gray CONNECTOR CONSOLE BOX LOCK RELEASE...

Page 28: ...HT BRAKE HOSE LEFT BRAKE HOSE THROTTLE CABLES WATER HOSES FRONT BRAKE HOSE FRONT BRAKE HOSE LEFT BRAKE LINE COMBINATION METER 28P Gray CONNECTOR SEAT CONSOLE BOX LOCK RELEASE BUTTON SWITCH 4P Black CO...

Page 29: ...LEFT TURN SIGNAL WIRE CONSOLE BOX LOCK CABLE LEFT TURN SIGNAL HEADLIGHT WIRE SEAT CONSOLE BOX LOCK RELEASE BUTTON WIRE CONSOLE BOX LOCK RELEASE ACTUATOR 2P Gray CONNECTOR LF ANTENNA WIRE MECHANICAL KE...

Page 30: ...RAKE LINE LF ANTENNA WIRE HANDLE LOCK MODULE 21P Gray CONNECTOR LED HOLDER 3P Black CONNECTOR HORN WIRE GROUND TERMINALS COOLING FAN MOTOR WIRE REAR BRAKE PIPE RADIATOR OVERFLOW HOSE RADIATOR SIPHONE...

Page 31: ...EAR BRAKE HOSE FRONT BRAKE PIPE LEFT BRAKE LINE HANDLE LOCK MODULE 21P Gray CONNECTOR LED HOLDER 3P Black CONNECTOR WHITE PAINT MARK LEFT BRAKE PIPE RIGHT BRAKE PIPE TURN SIGNAL RELAY WIRE RIGHT BRAKE...

Page 32: ...SOLE BOX LOCK CABLE ANSWER BACK DIODE SEAT CONSOLE BOX LOCK RELEASE BUTTON WIRE LF ANTENNA WIRE SEAT LOCK CABLE FUEL LID LOCK CABLE TURN SIGNAL RELAY SEAT LOCK CABLE FUEL LID LOCK CABLE CONSOLE BOX LO...

Page 33: ...INFORMATION 1 29 BREATHER HOSE A SEPARATOR BREATHER HOSE WHITE PAINT MARK BREATHER AIR HOSE BREATHER HOSE C WHITE PAINT MARK BREATHER HOSE B BREATHER HOSE A BREATHER HOSE B BREATHER HOSE C maxiscooter...

Page 34: ...RE SEAT LOCK CABLE CKP SENSOR 2P Red CONNECTOR REAR BRAKE PIPE MAIN HARNESS SPARK PLUG WIRE WATER HOSE REAR BRAKE HOSES ALTERNATOR 3P Black CONNECTOR PARKING BRAKE CABLE REAR BRAKE TURN SIGNAL LICENSE...

Page 35: ...GENERAL INFORMATION 1 31 MAIN HARNESS IGNITION COIL IGNITION COIL CONNECTORS SPARK PLUG WIRE ALTERNATOR WIRE maxiscooter club ru...

Page 36: ...JUNCTION 12P Black CONNECTOR ECM 33P Black CONNECTOR MAIN HARNESS THROTTLE CABLES SEAT LOCK CABLE WATER HOSES FUEL FEED HOSE THROTTLE CABLES WATER HOSES SIDESTAND SWITCH 2P Gray CONNECTOR GROUND TERM...

Page 37: ...HOSE WATER HOSES SPARK PLUG WIRE O2 SENSOR WIRE FUEL FEED HOSE O2 SENSOR 1P Black CONNECTOR PAIR CONTROL SOLENOID VALVE 2P Black CONNECTOR SECONDARY AIR SUPPLY HOSES RIGHT CRANKCASE COVER BREATHER HOS...

Page 38: ...ORMATION 1 34 THROTTLE CABLES PAIR CONTROL SOLENOID VALVE 2P Black CONNECTOR SENSOR UNIT 5P Black CONNECTOR ECT SENSOR 3P Gray CONNECTOR INJECTOR 2P Gray CONNECTOR ALTERNATOR WIRE WATER HOSES maxiscoo...

Page 39: ...GENERAL INFORMATION 1 35 RIGHT CRANKCASE BREATHER HOSE VS SENSOR WIRE VS SENSOR EOP SWITCH 4P Black CONNECTOR O2 SENSOR 1P Black CONNECTOR maxiscooter club ru...

Page 40: ...GENERAL INFORMATION 1 36 SEAT LOCK RELEASE ACTUATOR 2P Gray CONNECTOR GROUND CABLES MAIN HARNESS FUEL FEED HOSE SPARK PLUG WIRE FUEL PUMP UNIT 5P Natural CONNECTOR maxiscooter club ru...

Page 41: ...GENERAL INFORMATION 1 37 VS SENSOR WIRE EOP SWITCH WIRE GROUND CABLES THROTTLE CABLES WIRE HARNESS STARTER MOTOR CABLE VS SENSOR EOP SWITCH 4P Black CONNECTOR maxiscooter club ru...

Page 42: ...E VS SENSOR 3P Black CONNECTOR VS SENSOR STARTER RELAY SWITCH 4P Red CONNECTOR REGISTRATION 2P Red CONNECTOR EM MODE 2P Blue CONNECTOR RF UNIT 5P White CONNECTOR JUNCTION 20P Natural CONNECTOR JUNCTIO...

Page 43: ...ON 1 39 BATTERY CABLE MAIN HARNESS BATTERY CABLES BATTERY CABLE RF UNIT WIRE BATTERY CABLE LICENSE LIGHT MAIN HARNESS TURN SIGNAL TAIL BRAKE LIGHT 5P Gray CONNECTOR LICENSE LIGHT 3P Gray CONNECTOR max...

Page 44: ...IL BRAKE LIGHT 5P Gray CONNECTOR LICENSE LIGHT 3P Gray CONNECTOR RIGHT BRAKE TAIL LIGHT 3P Natural CONNECTOR RIGHT REAR TURN SIGNAL LIGHT WIRE LEFT REAR TURN SIGNAL LIGHT WIRE LEFT BRAKE TAIL LIGHT 3P...

Page 45: ...R RIGHT TURN SIGNAL POSITION HEADLIGHT 4P Blue CONNECTOR LEFT TURN SIGNAL LIGHT 3P Black CONNECTOR RIGHT TURN SIGNAL LIGHT 3P Natural CONNECTOR LEFT HEADLIGHT 3P Black CONNECTOR RIGHT HEADLIGHT 3P Nat...

Page 46: ...CONNECTOR BANK ANGLE SENSOR 3P Black CONNECTOR INSIDE BOOT CONNECTORS RIGHT HANDLEBAR SWITCH 8P Green CONNECTOR MODE SELECT SWITCH 2P Black CONNECTOR IGNITION SWITCH 2P Gray CONNECTOR LEFT HANDLEBAR S...

Page 47: ...CONNECTOR BANK ANGLE SENSOR WIRE INSIDE BOOT CONNECTORS RIGHT TURN SIGNAL POSITION HEADLIGHT 4P Blue CONNECTOR LEFT TURN SIGNAL POSITION HEADLIGHT 4P Gray CONNECTOR ANSWER BACK DIODE ABS CONTROL UNIT...

Page 48: ...RIGHT BRAKE HOSE LEFT BRAKE HOSE THROTTLE CABLES WATER HOSES FRONT BRAKE HOSE FRONT BRAKE HOSE LEFT BRAKE LINE COMBINATION METER 28P Gray CONNECTOR SEAT CONSOLE BOX LOCK RELEASE BUTTON 4P Black CONNE...

Page 49: ...LEFT TURN SIGNAL WIRE CONSOLE BOX LOCK CABLE LEFT TURN SIGNAL HEADLIGHT WIRE SEAT CONSOLE BOX LOCK RELEASE BUTTON WIRE LF ANTENNA WIRE MECHANICAL KEY CABLE FUEL LID LOCK CABLE SEAT LOCK CABLE BREATHER...

Page 50: ...GROUND TERMINALS COOLING FAN MOTOR WIRE REAR BRAKE PIPE RADIATOR OVERFLOW HOSE RADIATOR SIPHONE HOSE COOLING FAN MOTOR 2P Brown CONNECTOR PARKING BRAKE CABLE IGNITION SWITCH WIRE FRONT BRAKE HOSE LEFT...

Page 51: ...LINE HANDLE LOCK MODULE 21P Gray CONNECTOR LED HOLDER 3P Black CONNECTOR FRONT WHEEL SPEED SENSOR 2P Blue CONNECTOR LEFT BRAKE PIPE RIGHT BRAKE PIPE TURN SIGNAL RELAY WIRE RIGHT BRAKE PIPE LEFT BRAKE...

Page 52: ...SOLE BOX LOCK CABLE ANSWER BACK DIODE SEAT CONSOLE BOX LOCK RELEASE BUTTON WIRE LF ANTENNA WIRE SEAT LOCK CABLE FUEL LID LOCK CABLE TURN SIGNAL RELAY SEAT LOCK CABLE FUEL LID LOCK CABLE CONSOLE BOX LO...

Page 53: ...INFORMATION 1 49 BREATHER HOSE A SEPARATOR BREATHER HOSE WHITE PAINT MARK BREATHER AIR HOSE BREATHER HOSE C WHITE PAINT MARK BREATHER HOSE B BREATHER HOSE A BREATHER HOSE B BREATHER HOSE C maxiscooter...

Page 54: ...P Red CONNECTOR REAR BRAKE PIPE MAIN HARNESS SPARK PLUG WIRE WATER HOSE REAR BRAKE HOSES ALTERNATOR 3P Black CONNECTOR PARKING BRAKE CABLE REAR BRAKE TURN SIGNAL LICENSE LIGHT WIRE REGULATOR RECTIFIER...

Page 55: ...GENERAL INFORMATION 1 51 MAIN HARNESS IGNITION COIL IGNITION COIL CONNECTORS SPARK PLUG WIRE ALTERNATOR WIRE maxiscooter club ru...

Page 56: ...3P Black CONNECTOR MAIN HARNESS THROTTLE CABLES SEAT LOCK CABLE WATER HOSES FUEL FEED HOSE THROTTLE CABLES WATER HOSES SIDESTAND SWITCH 2P Gray CONNECTOR GROUND TERMINAL LUGGAGE BOX LIGHT WIRE PCM 21P...

Page 57: ...L FEED HOSE O2 SENSOR 1P Black CONNECTOR PAIR CONTROL SOLENOID VALVE 2P Black CONNECTOR SECONDARY AIR SUPPLY HOSES RIGHT CRANKCASE COVER BREATHER HOSE IACV 4P Black CONNECTOR VS SENSOR DRIVEN PULLEY S...

Page 58: ...ES SENSOR UNIT 5P Black CONNECTOR ECT SENSOR 3P Gray CONNECTOR INJECTOR 2P Gray CONNECTOR ALTERNATOR WIRE WATER HOSES MOVABLE DRIVE FACE POSITION SENSOR 3P Black CONNECTOR PAIR CONTROL SOLENOID VALVE...

Page 59: ...DRIVE PULLEY SENSOR WIRE DRIVEN SENSOR VS SENSOR EOP SWITCH MOVABLE DRIVE FACE POSITION SENSOR 10P Black CONNECTOR O2 SENSOR 1P Black CONNECTOR RATIO MOTOR 2P Black CONNECTOR REAR WHEEL SPEED SENSOR...

Page 60: ...ATION 1 56 GROUND CABLES MAIN HARNESS FUEL FEED HOSE SPARK PLUG WIRE FUEL PUMP UNIT 5P Natural CONNECTOR REAR WHEEL SPEED SENSOR 2P Orange CONNECTOR SEAT LOCK RELEASE ACTUATOR 2P Gray CONNECTOR maxisc...

Page 61: ...ND CABLES THROTTLE CABLES WIRE HARNESS STARTER MOTOR CABLE DRIVE SENSOR VS SENSOR EOP SWITCH MOVABLE DRIVE FACE POSITION SENSOR 10P Black CONNECTOR REAR WHEEL SPEED SENSOR 2P Orange CONNECTOR MOVABLE...

Page 62: ...CONNECTOR VS SENSOR REAR WHEEL SPEED SENSOR WIRE STARTER RELAY SWITCH 4P Red CONNECTOR REGISTRATION 2P Red CONNECTOR EM MODE 2P Blue CONNECTOR RF UNIT 5P White CONNECTOR JUNCTION 20P Natural CONNECTOR...

Page 63: ...ON 1 59 BATTERY CABLE MAIN HARNESS BATTERY CABLES BATTERY CABLE RF UNIT WIRE BATTERY CABLE LICENSE LIGHT MAIN HARNESS TURN SIGNAL TAIL BRAKE LIGHT 5P Gray CONNECTOR LICENSE LIGHT 3P Gray CONNECTOR max...

Page 64: ...IL BRAKE LIGHT 5P Gray CONNECTOR LICENSE LIGHT 3P Gray CONNECTOR RIGHT REAR TURN SIGNAL LIGHT WIRE LEFT REAR TURN SIGNAL LIGHT WIRE RIGHT BRAKE TAIL LIGHT 3P Natural CONNECTOR LEFT BRAKE TAIL LIGHT 3P...

Page 65: ...bon monoxide does not react in the same way but it is toxic Honda Motor Co Ltd utilizes various systems page 1 62 to reduce carbon monoxide oxides of nitrogen and hydrocarbons CRANKCASE EMISSION CONTR...

Page 66: ...m The PAIR control solenoid valve is operated by the solenoid valve The solenoid valve is controlled by the PGM FI unit and the fresh air passage is opened closed according the running conditions ECT...

Page 67: ...ivery to the ultimate customer or while it is in use 2 the use of any vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO...

Page 68: ...MEMO maxiscooter club ru...

Page 69: ...2 1 2 2 TECHNICAL FEATURES CLOSED CRANKCASE SYSTEM 2 2 Honda Smart Card Key System 2 4 HANDLE LOCK MODULE PCM ECM COMMUNICATION LINE 2 6 Honda S Matic System NSS250A 2 7 maxiscooter club ru...

Page 70: ...ough the oil filter and oil passage to the crankcase and cylinder head After lubricating the crankshaft the oil is returned to the oil room through the reed valve The reed valve prevent the oil from c...

Page 71: ...TECHNICAL FEATURES 2 3 BALANCER SEPARATE TYPE METAL BEARINGS REED VALVE CRANK ROOM maxiscooter club ru...

Page 72: ...taneously unlocking the Seat lock Console box lock Honda Smart Card Key System OPERATION The communication range of the Card Key is within 80 cm 31 5 in from the Seat Console box lock release button 1...

Page 73: ...Console box lock release actu ator starts up and pulls the lock cable 4 Seat Console box lock is unlocked MECHANICAL KEY LOCK OPERATION 1 Open the right inner box 2 Turn the mechanical key cylinder us...

Page 74: ...BAT 14 MAIN SW 17 FI ECU ENGINE STOP RELAY ENGINE STOP SWITCH BATTERY IGNITION SWITCH MAIN B FUSE 15 A NSS250A PCM HANDLE LOCK MODULE HANDLE LOCK MODULE BANK ANGLE SENSOR ECU IGN FUSE 10 A B11 IMOID M...

Page 75: ...The signal sent from the switch is received by the PCM The PCM coordinates the switch position and the conditions transmitted from various sensors and controls the Ratio Control Motor which alters th...

Page 76: ...izes running like the manual transmission by only operating the throttle D mode Example A mode Example High Low High angle low angle Time Braking Constant rate Acceleration Engine revolution Throttle...

Page 77: ...COMBINATION METER MODE SELECT SWITCH SHIFT SWITCH TP SENSOR CKP SENSOR MOVABLE DRIVE FACE POSITION SENSOR DRIVEN PULLEY SENSOR RATIO MOTOR FUSE 30 A PCM Bl Br Bu G O P R W Y Black Brown Blue Green Ora...

Page 78: ...The ratio control motor operated by the controlling current rotate the reduction gear A and B When rotating the reduction gear B the screw gear and movable drive face position sensor shaft are also ro...

Page 79: ...BODY LOWER COVER 3 10 BODY COVER 3 11 FLOOR STEP 3 12 REAR SPOILER 3 13 REAR BODY UPPER COVER REAR COMBINATION LIGHT 3 14 LUGGAGE LOWER BOX 3 16 SCREEN GARNISH 3 18 FRONT CENTER COVER 3 19 FRONT LOWE...

Page 80: ...Body cover page 3 11 5 Console box page 3 24 18 Meter visor page 3 18 6 Screen garnish page 3 18 19 Luggage box mat page 3 16 7 Handlebar post cover page 3 20 20 Luggage lower box page 3 16 8 Floor s...

Page 81: ...Floor mat 11 Front center cover 12 Floor step 10 Luggage lower box 20 Handle post cover 7 Front side cover 13 Rear meter panel 26 Inner cover 3 Screen garnish 6 Floor skirt 9 Front lower cover 16 Lugg...

Page 82: ...aust system Exhaust gas leak Poor performance Deformed exhaust system Exhaust gas leak Clogged muffler Exhaust pipe stud bolt 9 N m 0 9 kgf m 6 6 lbf ft See page 3 35 Exhaust pipe joint nut 29 N m 3 0...

Page 83: ...ck 2 Install the trim clip 3 Push the center pin until the pin is flush with the outer casing TRIM CLIP B REMOVAL 1 Push the center pin of the trim clip 2 Remove the trim clip REMOVAL 1 Raise the cent...

Page 84: ...ecessary Install the parts by inserting the snap fit clip straight into the hole being careful not to tilt the insertion of the clip FLOOR SIDE PANEL REMOVAL INSTALLATION Open the front seat Remove th...

Page 85: ...the seat hinge Remove the nuts and seat hinge from the front seat Install the seat hinge and nuts Tighten the seat hinge nuts to the specified torque Install the seat hinge cover seat hinge under cov...

Page 86: ...by sliding the rear seat for ward and releasing the tabs of the rear seat from the slots Install the rear seat by installing the tabs to the slots and bosses to the grommets Close the front seat FLOO...

Page 87: ...the front end of the floor skirt Release the trim clip hole of the floor skirt from the under cover Remove the floor skirt by releasing the rear end tab of the floor skirt from the floor step groove...

Page 88: ...nhooking the tabs hooks and snap fit clips from the slots Installation is in the reverse order of removal Make sure that the tabs hooks and snap fit clips of the rear body lower cover are properly ins...

Page 89: ...trim clip B and bolt washer Release the hooks of the body cover from the grooves of the rear body upper cover luggage box and floor step by slightly pulling the body cover rearward Installation is in...

Page 90: ...ve the screws bolt and bolt washers Release the front end tab and hooks of the floor step from the inner cover slots Remove the floor step by slightly sliding the floor step rearward Installation is i...

Page 91: ...lock cover from the rear spoiler Disconnect the luggage box light connectors and seat lock cable from the seat lock Remove the bolts and rear spoiler Installation is in the reverse order of removal Fi...

Page 92: ...he following Rear spoiler page 3 13 Body cover page 3 11 Disconnect the turn signal tail brake light 5P Gray and license light 3P Gray connectors Remove the bolts and screws from the rear combi nation...

Page 93: ...the tail brake light 3P and rear turn sig nal 2P connectors Remove the screws and rear body upper cover Assembly is in the reverse order of disassembly Route the wire properly page 1 21 SCREWS TURN S...

Page 94: ...ve the following Luggage box mat Body cover page 3 11 Rear body upper cover rear combination light page 3 14 Battery page 19 6 Remove the seat lock cable from the clamp Disconnect the luggage box ligh...

Page 95: ...open the starter relay cover Remove the wire band and starter relay switch from the fuse box cover Remove the screws and fuse relay box Remove the tab of the lower side fuse box cover from the frame...

Page 96: ...releasing the follow ing Front side tab of the screen garnish from the grommet of the right headlight unit Snap fit clips of the screen garnish from the holes of the front side covers Tabs of the scre...

Page 97: ...cover by releasing the fol lowing Front side tabs of the front center cover from the tabs of the screen garnish Front side tabs of the headlight unit from the holes of the front center cover Rear sid...

Page 98: ...VER REMOVAL INSTALLATION Open the console box Remove the screw Remove the handlebar post cover by releasing the tabs of the handlebar post cover from the holes of rear meter panel Installation is in t...

Page 99: ...emove the front side cover by releasing the follow ing Tabs of the headlight assembly from the grom mets of the frame Snap fit clips of the side cover from the holes of the left outer box inner cover...

Page 100: ...ht wire Remove the screws and headlight Remove the screws and front turn signal light Assembly is in the reverse order of disassembly REAR METER PANEL REMOVAL INSTALLATION Remove the front side cover...

Page 101: ...moval DISASSEMBLY ASSEMBLY Remove the screws A B speaker boxes and speaker grills Remove the screws and seat console box lock release button Remove the screws and combination meter For combination met...

Page 102: ...box locked and unlocked DISASSEMBLY ASSEMBLY LEFT INNER BOX Remove the screw and spring Remove the lock pin cap E clip washer wave washer collar and lock pin Remove the screws and left inner rail Rem...

Page 103: ...cable Remove the bolt and console box lock Remove the screws and left outer rails Assembly is in the reverse order of disassembly CONSOLE BOX LOCK CABLE CONSOLE BOX LOCK LEFT OUTER RAIL SCREWS HOLE B...

Page 104: ...verse order of removal Apply grease to the right inner box sliding sur face DISASSEMBLY ASSEMBLY Remove the screws and right inner box lid Remove the right inner box knob and spring from the right inn...

Page 105: ...the bolt washer Remove the inner cover by releasing the tab of the lower side inner cover from the hole of the frame and bosses of the front side inner cover from the holes of the grommet Installation...

Page 106: ...le box stay page 3 24 Remove the fuel lid knob and disconnect the fuel lid lock cable Remove the screws fuel lid lock cable stay and cable Remove the screws and left outer box FUEL LID LOCK CABLE FUEL...

Page 107: ...r Remove the screws and fuel lid stay from the inner cover Remove the screws and fuel lid from the stay Assembly is in the reverse order of removal INNER COVER SCREWS FUEL LID STAY INNER COVER FUEL LI...

Page 108: ...the reverse order of removal Hook the parking brake cable to the hooks of the under cover FRONT FENDER REMOVAL INSTALLATION Remove the socket bolts nut collars and front fender Install the front fende...

Page 109: ...light cover lens packing Screws license light base Bulb socket Remove the bolts bolt washers and rear fender Remove the nut and reflector Installation is in the reverse order of removal Be careful no...

Page 110: ...the muffler mounting bolts muffler and gasket Remove the exhaust pipe joint nuts Remove the exhaust pipe and gasket When removing the exhaust pipe protector remove the bolts and exhaust pipe protecto...

Page 111: ...tor install the exhaust pipe protector and tighten the bolts securely Install a new gasket to the cylinder head GASKET 29 N m 3 0 kgf m 21 lbf ft BOLTS EXHAUST PIPE 22 N m 2 2 kgf m 16 lbf ft PROTECTO...

Page 112: ...olts Tighten the muffler mounting bolts band bolt joint nuts to the specified torque in the specified sequence as follows Inspect the exhaust system for leak after tightening EXHAUST PIPE GASKET NUTS...

Page 113: ...s within specifications When removing the exhaust pipe stud bolts install and tighten new stud bolts into the cylinder head to the specified torque After tightening the stud bolts check that the lengt...

Page 114: ...MEMO maxiscooter club ru...

Page 115: ...4 12 RADIATOR COOLANT 4 13 COOLING SYSTEM 4 13 SECONDARY AIR SUPPLY SYSTEM 4 14 DRIVE BELT 4 15 BELT CASE AIR CLEANER 4 15 FINAL DRIVE OIL 4 16 BRAKE FLUID 4 17 BRAKE PADS WEAR 4 18 BRAKE SYSTEM 4 19...

Page 116: ...r except oils labeled as energy conserving on the circular API service label Viscosity SAE 10W 30 JASO T 903 Standard MB Valve clearance IN 0 16 0 03 mm 0 006 0 001 in EX 0 22 0 03 mm 0 009 0 001 in D...

Page 117: ...ALOC bolt replace with a new one Left side front cover socket bolt 10 N m 1 0 kgf m 7 lbf ft Left side rear cover socket bolt 10 N m 1 0 kgf m 7 lbf ft Master cylinder reservoir cap screw 1 5 N m 0 2...

Page 118: ...24 30 36 x 1 000 mi 0 6 4 8 12 16 20 24 ITEMS Months 6 12 18 24 30 36 FUEL LINE I I I 4 5 THROTTLE OPERATION I I I 4 5 AIR CLEANER NOTE 2 R R 4 6 CRANKCASE BREATHER NOTE 3 C C C C C C 4 7 SPARK PLUG R...

Page 119: ...ttle grip housing page 15 8 For cable lubrication Disconnect the throttle cable at its upper end Thoroughly lubricate the cable and its pivot point with a commercially available cable lubricant or a l...

Page 120: ...e lock nut After adjustment recheck the throttle operation Install the luggage lower box page 3 16 AIR CLEANER The viscous paper element type air cleaner can not be cleaned because the element contain...

Page 121: ...e the luggage lower box page 3 16 Check the crankcase breather hose and replace it if the crankcase breather hose is deteriorated dam aged or leaked Also check the crankcase breather hose fittings for...

Page 122: ...gauge of a wire type If necessary adjust the spark plug gap by bending the side electrode carefully Do not overtighten the spark plug Install the spark plug in the cylinder head and hand tighten then...

Page 123: ...rd each valve clearance Slide the rocker arms to the spring side and remove the shims Do not allow the shims to fall into the crankcase Mark all shims to ensure correct reassembly in their original lo...

Page 124: ...ll the shims To accustom the shims rotate the camshaft several times by turning the drive pulley face crankshaft Recheck each valve clearance Install the removed parts in the reverse order of removal...

Page 125: ...and sealing washer Drain the engine oil completely Clean the oil drain bolt and apply oil to the oil drain bolt threads Install the drain bolt with a new sealing washer and tighten it Pour the recomm...

Page 126: ...l with engine warm and the scooter on its center stand to assure complete and rapid drain ing Start the engine warm it up and stop it Drain the engine oil from the crankcase page 4 11 Remove the oil f...

Page 127: ...lid and fill the tank to the UPPER level line with a 1 1 mix ture of distilled water and antifreeze coolant mix ture preparation page 7 6 Check to see if there are any coolant leaks if the coolant lev...

Page 128: ...secondary air supply system The pulse secondary air sup ply system is located on the cylinder The secondary air supply system introduces fil tered air into exhaust gases in the exhaust port The second...

Page 129: ...th page 11 13 Install the left side rear cover page 4 15 BELT CASE AIR CLEANER REMOVAL INSTALLATION Remove the socket bolts and left side rear cover Remove the left floor step page 3 12 Remove the soc...

Page 130: ...low oil does not flow out pour the recommended oil as follows pour the recom mended final drive oil through the oil check bolt hole until it reaches the lower edge of the hole Install the oil check bo...

Page 131: ...hey are not compatible with each other Do not allow foreign material to enter the system when filling the reservoir BRAKE FLUID LEVEL INSPECTION Turn the handlebar so that the reservoir is level and c...

Page 132: ...ecified torque BRAKE PADS WEAR FRONT BRAKE PADS Check the brake pads for wear Replace the brake pads if either pad reaches the wear limit groove For the front brake pad replacement page 17 14 CASTING...

Page 133: ...tings for deteriora tion cracks damage or signs of leakage Tighten any loose fittings to the specified torque Replace hoses and fittings as required CBS INSPECTION This model is equipped with a CBS Ch...

Page 134: ...ake lever by pulling it Pull the parking brake lever slowly and count the number of notch until the parking brake lever is locked If it is out of standard adjust the parking brake page 4 20 ADJUSTMENT...

Page 135: ...age 22 7 Support the scooter on its center stand Adjust the headlight beam vertically by turning the adjuster A Adjust the headlight beam horizontally by turning the adjuster B Install the removed par...

Page 136: ...nd spring bolt nut and sidestand Installation is in the reverse order of removal Replace the sidestand pivot bolt and sidestand switch bolt with a new one Apply grease to the sidestand sliding surface...

Page 137: ...fasteners Replace damaged components which cannot be repaired page 16 16 Tighten all nuts and bolts Support the scooter using a jack or other support Check for worn engine mounting bushings by grab b...

Page 138: ...its center stand and raise the rear wheel off the ground Hold the swingarm and move the rear wheel side ways forcefully to see if the final bearings or swingarm bearing are worn Replace the final bea...

Page 139: ...ise the front wheel off the ground and support the scooter securely Check that the handlebar moves freely from side to side Hold the scooter and check the steering head bear ings for wear by moving th...

Page 140: ...MEMO maxiscooter club ru...

Page 141: ...ICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 5 2 SERVICE INFORMATION 5 3 TROUBLESHOOTING 5 4 OIL PRESSURE INSPECTION 5 5 OIL STRAINER 5 6 OIL PRESSURE RELIEF VALVE 5 7 REED VALVE 5 8 OIL PUMP 5 9 maxisco...

Page 142: ...CATION SYSTEM LUBRICATION SYSTEM DIAGRAM CAMSHAFT MAIN JOURNAL BEARING CRANKSHAFT EOP SWITCH OIL FILTER CARTRIDGE OIL PRESSURE RELIEF VALVE REED VALVE OIL STRAINER SCREEN OIL PUMP MAIN JOURNAL BEARING...

Page 143: ...ed oil ITEM STANDARD SERVICE LIMIT Engine oil capacity After draining 1 3 liter 1 4 US qt 1 1 Imp qt After oil filter change 1 4 liter 1 5 US qt 1 2 Imp qt After disassembly 1 7 liter 1 8 US qt 1 5 Im...

Page 144: ...eing used No oil pressure Oil level too low Oil pressure relief valve stuck open Broken oil pump drive chain Broken oil pump drive or driven sprocket Damaged oil pump Damaged oil pump shaft Internal o...

Page 145: ...he engine speed to 5 000 min 1 rpm and read the oil pressure Stop the engine and remove the tools Apply sealant to the threads of the EOP switch Install the EOP switch and tighten it to the specified...

Page 146: ...or damage or clogs INSTALLATION Install the oil strainer into the crankcase Face the arrow to upside Install the oil strainer screen with tapered side fac ing the crankcase Install the right crankcase...

Page 147: ...damage Remove the pin and clip from the relief valve Check the pin and clip for bend or wear Once the clip is removed from the relief valve replace it with a new one Clean all parts and assemble the...

Page 148: ...Assemble the crankcase page 14 21 REED VALVE REMOVAL Separate the crankcase page 14 5 Remove the reed valve to the left crankcase Check the reed valve for wear or damage Install the reed valve into th...

Page 149: ...ocket has left hand threads Remove the bolt and oil pump driven sprocket from the oil pump Remove the bolts and oil pump from the right crankcase DISASSEMBLY Remove the screw Remove the dowel pins and...

Page 150: ...compare the service limit If any portion of the oil pump is worn beyond the specified service limits replace the oil pump and oil pump cover as an assembly TIP CLEARANCE Temporarily install the outer...

Page 151: ...r gauge SIDE CLEARANCE Measure the side clearance using a straight edge and feeler gauge ASSEMBLY SERVICE LIMIT 0 35 mm 0 014 in BODY CLEARANCE SERVICE LIMIT 0 12 mm 0 005 in SIDE CLEARANCE OUTER ROTO...

Page 152: ...t washer Install the dowel pins Install the oil pump cover onto the oil pump body by aligning the dowel pins on the body and holes of the cover Install and tighten the oil pump cover screw to the spec...

Page 153: ...driven sprocket bolt threads Install and tighten the oil pump driven sprocket bolt to the specified torque Install the driven sprocket cover and tighten the bolt Install the right crankcase cover pag...

Page 154: ...MEMO maxiscooter club ru...

Page 155: ...A 6 22 DTC TROUBLESHOOTING NSS250S 6 24 DTC TROUBLESHOOTING NSS250A 6 36 MIL TROUBLESHOOTING NSS250S 6 48 MIL TROUBLESHOOTING NSS250A 6 58 MIL CIRCUIT INSPECTION 6 67 FUEL LINE INSPECTION 6 71 FUEL PU...

Page 156: ...FUEL SYSTEM PGM FI 6 2 FUEL SYSTEM PGM FI COMPONENT LOCATION 11 N m 1 1 kgf m 8 lbf ft maxiscooter club ru...

Page 157: ...ly connected or corroded connectors Check those connections before proceeding When disassembling the PGM FI parts note the location of the O rings Replace them with new ones upon reassembly Use a digi...

Page 158: ...essure gauge manifold 07ZAJ S5A0111 Hose attachment 9 mm 9 mm 07ZAJ S5A0120 Hose attachment 6 mm 9 mm 07ZAJ S5A0130 Attachment joint 6 mm 9 mm 07ZAJ S5A0150 SCS connector 070PZ ZY30100 ECM test harnes...

Page 159: ...related circuit Faulty fuel injector Engine stalls hard to start rough idling 1 Inspect the idle speed page 6 102 2 Inspect the IACV page 6 103 3 Inspect the fuel supply system page 6 71 4 Inspect the...

Page 160: ...RECTIFIER INJECTOR DLC COMBINATION METER ENGINE STOP SWITCH HANDLE LOCK MODULE BANK ANGLE SENSOR FAN MOTOR FUEL PUMP UNIT IGNITION COIL FUSE RELAY BOX ENGINE STOP RELAY FUEL PUMP RELAY FAN CONTROL REL...

Page 161: ...NJECTOR DLC COMBINATION METER ENGINE STOP SWITCH HANDLE LOCK MODULE BANK ANGLE SENSOR FAN MOTOR FUEL PUMP UNIT IGNITION COIL FUSE RELAY BOX ENGINE STOP RELAY FUEL PUMP RELAY FAN CONTROL RELAY ECT SENS...

Page 162: ...DLC SCS CONNECTOR FAN MOTOR 2P Br FAN CONTROL RELAY FUEL PUMP FUEL PUMP RELAY IGNITION COIL ECM INJECTOR BANK ANGLE SENSOR ENGINE STOP RELAY ENGINE STOP SWITCH IGNITION SWITCH ECU IGN FUSE 10 A METER...

Page 163: ...male terminals CPU MIL COMBINATION METER DLC SCS CONNECTOR FAN MOTOR FAN CONTROL RELAY FUEL PUMP FUEL PUMP RELAY IGNITION COIL INJECTOR BANK ANGLE SENSOR ENGINE STOP RELAY ENGINE STOP SWITCH IGNITION...

Page 164: ...FUEL SYSTEM PGM FI 6 10 PGM FI CONNECTOR LOCATIONS NSS250S NOTE 1 Remove the left body cover page 3 11 NOTE 2 Remove the battery cover page 19 6 ECM 33P Black CONNECTOR DLC 4P Red maxiscooter club ru...

Page 165: ...GM FI 6 11 NOTE 3 Remove the luggage lower box page 3 16 SENSOR UNIT 5P Black CONNECTOR IACV 4P Black CONNECTOR O2 SENSOR Black CONNECTOR INJECTOR 2P Gray CONNECTOR ECT SENSOR 3P Gray CONNECTOR maxisc...

Page 166: ...FUEL SYSTEM PGM FI 6 12 NSS250A NOTE 1 Remove the left body cover page 3 11 NOTE 2 Remove the battery cover page 19 6 PCM 21P Black CONNECTOR B PCM 33P Black CONNECTOR A DLC 4P Red maxiscooter club ru...

Page 167: ...GM FI 6 13 NOTE 3 Remove the luggage lower box page 3 16 SENSOR UNIT 5P Black CONNECTOR IACV 4P Black CONNECTOR O2 SENSOR Black CONNECTOR INJECTOR 2P Gray CONNECTOR ECT SENSOR 3P Gray CONNECTOR maxisc...

Page 168: ...nosis function running capability is maintained by pre programmed values in the simulated program map When any abnormality is detected in the injector the fail safe function stops the engine to protec...

Page 169: ...the failure status In the case that the PCM ECM detects a problem at present the MIL will come on and will start to blink the DTC when the sidestand is lowered In the case that the PCM ECM does not d...

Page 170: ...ut HDS 1 Remove the battery cover page 19 6 2 Turn the ignition switch OFF 3 Remove the dummy connector and short the Brown and Green black wire terminals of the DLC using a special tool 4 Turn the ig...

Page 171: ...e test probe into the connector terminal then attach the digital multimeter probe to the test probe TEST HARNESS CONNECTION NSS250S Remove the left body cover page 3 11 Turn the ignition switch OFF Di...

Page 172: ...CM ECM connector terminals are numbered as shown in the illustration The test harness terminals are same layout as for the PCM ECM con nector terminals as shown TOOL ECM test harness 33P 070MZ MCA0100...

Page 173: ...ction Poor engine acceleration Pre programmed value 0 S 6 28 A 6 40 S 6 51 A 6 61 8 2 8 TP sensor circuit high voltage more than 4 922 V TP sensor or its circuit malfunction Poor engine acceleration P...

Page 174: ...33P Black connector page 6 98 Check the continuity at the Yellow red and Green orange wires between the sensor unit 5P and ECM 33P connectors Is there continuity YES GO TO STEP 3 NO Open circuit in Y...

Page 175: ...Black connector Turn the ignition switch ON and engine stop switch Measure the voltage at the wire side Is the voltage within 4 75 5 25 V YES Turn the ignition switch OFF Connect the sensor unit 5P B...

Page 176: ...ignition switch OFF and dis connect the sensor unit 5P Black con nector and start the DTC troubleshooting page 6 36 NO GO TO STEP 2 2 Sensor Unit Power Line Open Circuit Inspection Turn the ignition s...

Page 177: ...ition switch ON Measure the voltage at the test harness termi nals Is the voltage within 4 75 5 25 V YES GO TO STEP 2 NO Replace the PCM with a known good one and recheck 2 Sensor Unit Power Input Vol...

Page 178: ...lure DTC TROUBLESHOOTING NSS250S DTC 1 1 MAP SENSOR LOW VOLTAGE 1 MAP Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the MAP sensor with the HDS pocket tester Is abo...

Page 179: ...he MAP sensor with the HDS pocket tester Is DTC 1 1 indicated YES Replace the ECM with a known good one and recheck NO Faulty original sensor unit MAP sensor DTC 1 2 MAP SENSOR HIGH VOLTAGE 1 MAP Sens...

Page 180: ...good one and recheck NO Open circuit in Yellow orange wire DTC 7 1 ECT SENSOR LOW VOLTAGE 1 ECT Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the ECT sensor with th...

Page 181: ...with a known good one and recheck DTC 7 2 ECT SENSOR HIGH VOLTAGE Before starting the inspection check for loose or poor contact on the ECT sensor 3P Gray con nector and recheck the HDS pocket tester...

Page 182: ...reen orange wire DTC 8 1 TP SENSOR LOW VOLTAGE 1 TP Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the TP sensor with the HDS pocket tester when throttle fully close...

Page 183: ...d one page 6 88 Erase the DTC s page 6 16 Connect the sensor unit 5P Black and ECM 33P Black connectors Turn the ignition switch ON and engine stop switch Check the TP sensor with the HDS pocket teste...

Page 184: ...the sensor unit 5P Black connector Measure the voltage at the wire side Is the voltage within 4 75 5 25 V YES Replace the ECM with a known good one and recheck NO Open circuit in White red wire DTC 9...

Page 185: ...5P Black connector 2 Sensor Unit Power Line Inspection Check the sensor unit power line inspection page 6 20 Is the sensor unit power line normal YES GO TO STEP 3 NO Replace or repair the abnormal ci...

Page 186: ...n switch OFF Disconnect the injector 2P Gray connector Turn the ignition switch ON and engine stop switch Measure the voltage between the injector 2P connector of the wire side and ground Is there bat...

Page 187: ...2 sensor cap is disconnected replace the O2 sensor cord with a new one Before starting the inspection check for loose or poor contact on the O2 sensor 1P Black connec tor or O2 sensor cap and recheck...

Page 188: ...nspection Replace the O2 sensor and O2 sensor cord with a new one page 6 107 Erase the DTC s page 6 16 Connect the O2 sensor 1P Black connector Turn the ignition switch ON and engine stop switch Start...

Page 189: ...circuit in Light green red Brown red Black red or Gray red wire NO GO TO STEP 3 3 IACV Open Circuit Inspection Disconnect the ECM 33P Black connector Check the continuity between the ECM 33P and IACV...

Page 190: ...nown good one and recheck NO Intermittent failure DTC TROUBLESHOOTING NSS250A DTC 1 1 MAP SENSOR LOW VOLTAGE 1 MAP Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the...

Page 191: ...he MAP sensor with the HDS pocket tester Is DTC 1 1 indicated YES Replace the PCM with a known good one and recheck NO Faulty original sensor unit MAP sensor DTC 1 2 MAP SENSOR HIGH VOLTAGE 1 MAP Sens...

Page 192: ...good one and recheck NO Open circuit in Yellow orange wire DTC 7 1 ECT SENSOR LOW VOLTAGE 1 ECT Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the ECT sensor with th...

Page 193: ...lace the PCM with a known good one and recheck DTC 7 2 ECT SENSOR HIGH VOLTAGE Before starting the inspection check for loose or poor contact on the ECT sensor 3P Gray con nector and recheck the HDS p...

Page 194: ...reen orange wire DTC 8 1 TP SENSOR LOW VOLTAGE 1 TP Sensor System Inspection Turn the ignition switch ON and engine stop switch Check the TP sensor with the HDS pocket tester when throttle fully close...

Page 195: ...rt circuit in White red wire NO GO TO STEP 5 5 TP Sensor Inspection Replace the sensor unit with a known good one page 6 88 Erase the DTC s page 6 16 Connect the sensor unit 5P Black and PCM 33P Black...

Page 196: ...e grip Is the resistance within 0 6 k Is the resis tance changed by operating the throttle grip YES GO TO STEP 4 NO Faulty sensor unit TP sensor 4 TP Sensor Ground Line Inspection Turn the ignition sw...

Page 197: ...nsor with the HDS pocket tester Is about 5 V indicated YES GO TO STEP 2 NO Intermittent failure Loose or poor contact on the sensor unit 5P Black connector 2 Sensor Unit Power Line Inspection Check th...

Page 198: ...n switch OFF Disconnect the injector 2P Gray connector Turn the ignition switch ON and engine stop switch Measure the voltage between the injector 2P connector of the wire side and ground Is there bat...

Page 199: ...2 sensor cap is disconnected replace the O2 sensor cord with a new one Before starting the inspection check for loose or poor contact on the O2 sensor 1P Black connec tor or O2 sensor cap and recheck...

Page 200: ...nspection Replace the O2 sensor and O2 sensor cord with a new one page 6 107 Erase the DTC s page 6 16 Connect the O2 sensor 1P Black connector Turn the ignition switch ON and engine stop switch Start...

Page 201: ...circuit in Light green red Brown red Black red or Gray red wire NO GO TO STEP 3 3 IACV Open Circuit Inspection Disconnect the PCM 33P Black connector Check the continuity between the PCM 33P and IACV...

Page 202: ...NSS250S MIL 1 BLINK MAP SENSOR 1 Sensor Unit Power Line Inspection Check the sensor unit power line inspection page 6 22 Is the sensor unit power line normal YES GO TO STEP 2 NO Replace or repair of t...

Page 203: ...ontinuity YES Short circuit in Yellow orange wire NO GO TO STEP 5 5 MAP Sensor Output Line Open Circuit Inspection 2 Check the continuity between the test harness and sensor unit 5P connector of the w...

Page 204: ...nnector Turn the ignition switch ON and engine stop switch Measure the voltage at the ECT sensor 3P con nector of the wire side and ground Is the voltage within 4 75 5 25 V YES GO TO STEP 5 NO GO TO S...

Page 205: ...ine inspection page 6 20 Is the sensor unit power line normal YES GO TO STEP 2 NO Replace or repair the abnormal circuit 2 TP Sensor Output Voltage Inspection Turn the ignition switch ON and engine st...

Page 206: ...Open circuit in White red wire MIL 9 BLINKS IAT SENSOR 1 Sensor Unit Power Line Inspection Check the sensor unit power line inspection page 6 20 Is the sensor unit power line normal YES GO TO STEP 2...

Page 207: ...he wire side and ground Is there continuity YES Short circuit in White blue wire NO GO TO STEP 5 5 IAT Sensor Voltage Output Line Open Circuit Inspection Check the continuity between the sensor unit 5...

Page 208: ...urn the ignition switch ON and engine stop switch Measure the voltage between the injector 2P connector of the wire side and ground Is there battery voltage YES GO TO STEP 2 NO Open or short circuit i...

Page 209: ...S O2 SENSOR Do not reuse O2 sensor cord if the O2 sensor cap is disconnected replace the O2 sensor cord with a new one Before starting the inspection check for loose or poor contact on the O2 sensor 1...

Page 210: ...GO TO STEP 4 4 O2 Sensor Inspection Replace the O2 sensor and O2 sensor cord with a new one page 6 107 Disconnect the test harness and connect the ECM 33P Black connector Turn the ignition switch ON...

Page 211: ...ircuit in Brown red Gray red Light green red or Black red wire 3 IACV Resistance Inspection Disconnect the test harness of the ECM 33P Black connector side Connect the IACV 4P Black connector Measure...

Page 212: ...or unit 5P Black connector Turn the ignition switch ON and engine stop switch Measure the voltage at the wire side Is the voltage within 4 75 5 25 V YES Faulty sensor unit MAP sensor NO GO TO STEP 4 4...

Page 213: ...the voltage at the test harness termi nals Is the voltage within 2 7 3 1 V 20 C 68 F YES Loose or poor contact on the PCM connector Intermittent failure NO GO TO STEP 2 2 ECT Sensor Input Voltage Insp...

Page 214: ...Pink white wire NO GO TO STEP 5 5 ECT Sensor Resistance Inspection Turn the ignition switch OFF Measure the resistance at the ECT sensor termi nals Is the resistance within 2 3 2 6 k 20 C 68 F YES Re...

Page 215: ...onnect the sensor unit 5P Black connector Check the continuity between the sensor unit 5P connector of the wire side and ground Is there continuity YES Short circuit in White red wire NO GO TO STEP 4...

Page 216: ...e sensor unit 5P Black connector Turn the ignition switch ON and engine stop switch Measure the voltage at the sensor unit 5P con nector of the wire side Is the voltage within 4 75 5 25 V YES GO TO ST...

Page 217: ...INJECTOR Before starting the inspection check for loose or poor contact on the injector 2P Gray connector and recheck the MIL blinking 1 Injector Input Voltage Inspection Turn the ignition switch OFF...

Page 218: ...nnector of the wire side and ground Is there continuity YES Short circuit in Pink blue wire NO GO TO STEP 4 4 Injector Resistance Inspection Measure the resistance of the injector connector terminals...

Page 219: ...ensor Open Circuit Inspection Connect the test harness to the PCM 33P connec tor page 6 17 Disconnect the O2 sensor 1P Black connector Check the continuity between the test harness and O2 sensor 1P co...

Page 220: ...n Turn the ignition switch OFF Check the continuity between the IACV 4P con nector of the wire side and ground Is there continuity YES Short circuit in Light green red Brown red Black red or Gray red...

Page 221: ...f the engine can be started but the MIL does not come on when the ignition switch is turned ON Check for the combination meter function If it does not function check the combination meter page 22 10 I...

Page 222: ...d the PCM ECM 33P Black connector termi nal of the wire side connector with a jumper wire Turn the ignition switch ON and engine stop switch the MIL should come on If the MIL come on replace the PCM E...

Page 223: ...rly check as follows MIL and DLC circuit inspection with test probe Turn the ignition switch OFF Remove the left body cover page 3 11 Disconnect the PCM ECM 33P Black connector Turn the ignition switc...

Page 224: ...7 Check the continuity between the test harness and ground If there is continuity check the White wire for short circuit between the combination meter and PCM ECM If the MIL comes on replace the combi...

Page 225: ...fuel pressure page 6 71 2 Check the fuel quick connect fitting for dirt and clean if necessary Place a shop towel over the quick connect fitting 3 Pull and release the rubber cap as shown 4 Hold the...

Page 226: ...one hand and squeeze the retainer tabs with the other hand to release them from the locking pawls Pull the connector off then remove the retainer from the injector joint Absorb the remaining fuel in t...

Page 227: ...cifications Do not bent or twist the fuel feed hose If the rubber cap or connector damper is dam aged or cut replace it with a new one FUEL PUMP UNIT SIDE 1 Insert a new retainer into the connector Al...

Page 228: ...r joint as shown 3 Install the connector to the injector joint Then press the quick connect fitting onto the injector joint until both retainer pawls lock with a CLICK If it is hard to connect put a s...

Page 229: ...p unit 5P Natural connector and negative cable to the battery Start the engine and let it idle Read the fuel pressure If the fuel pressure is higher than specified replace the fuel pump unit If the fu...

Page 230: ...0 seconds Measure the amount of fuel flow If the fuel flow is less than specified inspect the fol lowing Clogged fuel filter Faulty fuel pump unit Clogged fuel cap breather hole Fuel pump unit page 6...

Page 231: ...l pump relay page 6 79 Handle lock module page 23 19 Bank angle sensor page 6 92 NSS250S ECM page 6 95 NSS250A PCM page 6 99 REMOVAL Disconnect the quick connect fitting from the fuel pump unit page 6...

Page 232: ...acing to left Be careful not to damage the fuel level sensor when installing the fuel pump unit Install the set plate to the fuel pump unit by aligning the holes and tabs Be careful not to damage the...

Page 233: ...llowing Fuel pump relay Engine stop relay Connect the ohmmeter to the relay connector termi nals Connect the 12 V battery to the following relay con nector terminals There should be continuity only wh...

Page 234: ...the reverse order of removal Always replace the lower side of the fuel tank mounting bolt with a new one Route the wire harness properly page 1 21 AIR CLEANER HOUSING REMOVAL Be careful not to damage...

Page 235: ...e air cleaner housing Tighten the connecting boot band screw to the specified torque Install the air cleaner housing mounting bolt wash ers and tighten its bolts to the specified torque Install the fo...

Page 236: ...lock nuts and disconnect the throttle cables from the throttle drum and cable guide Remove the clamp Disconnect the sensor unit 5P Black and IACV 4P Black connectors Loosen the connecting boot and in...

Page 237: ...or tight ening them can cause throttle valve and idle con trol failure When removing the sensor unit perform the throttle valve fully closed reset procedure page 6 90 Remove the following Sensor unit...

Page 238: ...rews to specified torque Connect the sensor unit 5P Black and IACV 4P Black connectors Install the clamp to the stay Connect the throttle cables to the throttle drum Adjust the throttle grip freeplay...

Page 239: ...O rings DISASSEMBLY Loosen the screw and remove the insulator B from intake pipe ASSEMBLY Install the insulator B while aligning its slot with the lug on the intake pipe Tighten the insulator band sc...

Page 240: ...ecified torque Install the injector page 6 87 INJECTOR REMOVAL Disconnect the quick connect fitting from the injec tor page 6 71 Remove the luggage lower box page 3 16 Clean around the injector base w...

Page 241: ...ing and seal ring being careful not to damage Install the injector into the injector joint being care ful not to damage the O ring by aligning the lug of the injector joint with the connector of the i...

Page 242: ...onnect the injector 2P Gray connector Install the luggage lower box page 3 16 SENSOR UNIT REMOVAL Remove the luggage lower box page 3 16 Disconnect the 5P Black connector Remove the torx screws and se...

Page 243: ...t to the throttle body by align ing the clip of the TP sensor and boss of the throttle drum Install the torx screws and tighten them to the spec ified torque Connect the sensor unit 5P Black connector...

Page 244: ...ge 3 16 5 Temporarily install the battery page 19 6 6 Turn the ignition switch OFF 7 Disconnect the ECT sensor 3P Gray connector Short the ECT sensor 3P connector terminals of the wire side using the...

Page 245: ...er box page 3 16 15 Disconnect the DLC from the SCS connector Install the dummy connector 16 Install the battery cover page 19 6 17 Support the scooter on its center stand Start the engine let it idle...

Page 246: ...nstall the intake pipe page 6 85 Install the luggage lower box page 3 16 Fill and bleed the cooling system with recom mended coolant page 7 6 BANK ANGLE SENSOR SYSTEM INSPECTION Place the scooter on i...

Page 247: ...Line Inspection Turn the ignition switch OFF Disconnect the bank angle sensor 3P Black con nector page 6 94 Turn the ignition switch ON and engine stop switch Measure the voltage at the bank angle se...

Page 248: ...con nector and remove the connector clamp Remove the screws and bank angle sensor Route the sensor wire correctly page 1 21 Install the bank angle sensor with its UP mark fac ing up and back Tighten...

Page 249: ...ground Is there continuity YES Intermittent failure NO Open circuit in Green wire Open circuit in Green black wire 3 Engine Stop Relay Inspection 1 Remove the engine stop relay page 6 79 Turn the ign...

Page 250: ...heck for loose or poor contact on the ECM 33P Black connector and recheck the MIL blinking Engine does not start MIL no blinks 1 Input Voltage Inspection Turn the ignition switch OFF Connect the test...

Page 251: ...engine stop relay page 6 79 Turn the ignition switch ON and engine stop switch Measure the voltage at the fuse relay box termi nals of wire side Is there battery voltage YES GO TO STEP 4 NO Open circ...

Page 252: ...k white wire between the engine stop relay and the ECM REMOVAL INSTALLATION Remove the left body cover page 3 11 Turn the ignition switch OFF Disconnect the 33P Black connector Remove the ECM from the...

Page 253: ...re continuity YES Intermittent failure NO Open circuit in Green wire Open circuit in Green black wire 3 Engine Stop Relay Inspection 1 Turn the ignition switch OFF Remove the engine stop relay page 6...

Page 254: ...heck for loose or poor contact on the PCM 33P Black connector and recheck the MIL blinking Engine does not start MIL no blinks 1 Input Voltage Inspection Turn the ignition switch OFF Connect the test...

Page 255: ...own fuse MAIN B and or ECU IGN fuse Faulty bank angle sensor 4 Engine Stop Relay Inspection 2 Turn the ignition switch OFF Jump the engine stop relay connector terminals Turn the ignition switch ON an...

Page 256: ...Air cleaner condition page 4 6 The engine must be warm for accurate idle speed inspection This system eliminates the need for manual idle speed adjustment from the previous designs Use a tachometer wi...

Page 257: ...the battery Connect the IACV 4P Black connector and turn the ignition switch ON and engine stop switch The IACV slide valve will move to slide body and then move out the slide body while guiding the...

Page 258: ...the guide pin in the throttle body Install the IACV retainer while aligning its groove with the tab of the IACV Install and tighten the torx screws to the specified torque Connect the IACV 4P Black co...

Page 259: ...ertain that air is sucked in through the air intake port If the air is not drawn in check the air supply hoses for clogs and the PAIR control solenoid valve page 6 105 PAIR CONTROL SOLENOID VALVE REMO...

Page 260: ...e terminals of the PAIR control solenoid valve If the resistance is out of specification replace the PAIR control solenoid valve Install the PAIR control solenoid valve page 6 105 PAIR CHECK VALVE REM...

Page 261: ...ed if dropped Replace it with a new one if dropped If the O2 sensor cap is disconnected replace the O2 sensor cord with a new one do not reuse O2 sensor cord REMOVAL Handle the O2 sensor with care Do...

Page 262: ...fied torque Connect the O2 sensor cap of a new O2 sensor cord Take care not to tilt the O2 sensor cap when con necting the cap to the O2 sensor Do not turn the O2 sensor cap after connecting it Route...

Page 263: ...STEM FLOW PATTERN 7 2 SERVICE INFORMATION 7 3 TROUBLESHOOTING 7 4 SYSTEM TESTING 7 5 COOLANT REPLACEMENT 7 6 THERMOSTAT 7 10 WATER PUMP 7 11 RADIATOR 7 14 RADIATOR RESERVE TANK 7 17 FAN CONTROL RELAY...

Page 264: ...COOLING SYSTEM 7 2 COOLING SYSTEM SYSTEM FLOW PATTERN WATER PUMP RESERVE TANK SIPHON HOSE RADIATOR CAP THERMOSTAT RESERVE TANK OVERFLOW HOSE maxiscooter club ru...

Page 265: ...le the engine is hot can allow the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap ITEM SPECIFICATIONS Coolant capacity Radiat...

Page 266: ...too low Thermostat stuck open Fault cooling fan motor circuit Faulty ECT sensor and or its circuit page 22 24 Faulty fan control relay Coolant leaks Faulty water pump mechanical seal Deteriorated O ri...

Page 267: ...06 1 005 1 003 1 001 0 999 0 997 10 1 018 1 017 1 017 1 016 1 015 1 014 1 013 1 011 1 009 1 007 1 005 15 1 028 1 027 1 026 1 025 1 024 1 022 1 020 1 018 1 016 1 014 1 012 20 1 036 1 035 1 034 1 033 1...

Page 268: ...for at least 6 seconds Remove the tester and install the radiator cap Install the left floor side panel page 3 6 COOLANT REPLACEMENT PREPARATION The effectiveness of coolant decreases with the accumu...

Page 269: ...hose and completely drain the residual coolant Remove the reserve tank maintenance lid Open the tank cap and drain the coolant from the system Disconnect the radiator hoses and completely drain the r...

Page 270: ...ge box mat page 3 16 Remove the maintenance lid Remove the air bleed bolt and sealing washer Fill the coolant from the filler neck until the coolant starts flowing from the bolt hole UPPER LINE MAINTE...

Page 271: ...engine and let it idle for 2 3 minutes 2 Snap the throttle three four times to bleed air from the system 3 Stop the engine and add coolant up to the filler neck Reinstall the radiator cap 4 Check the...

Page 272: ...ve the thermostat page 7 10 Visually inspect the thermostat for damage Check for damage of the seal ring Replace the thermostat if the valve stays open at room temperature Do not let the thermostat or...

Page 273: ...ght crankcase cover page 13 4 Remove the bolt sealing washer water pump cover O ring and dowel pins The impeller has left hand threads Hold the water pump shaft and remove the impeller and washer Remo...

Page 274: ...ION Degrease the pump shaft thoroughly and apply molybdenum oil solution to the water pump shaft rolling area and thrust washer sliding surface Do not apply molybdenum oil solution to the mechanical s...

Page 275: ...impeller Hold the pump shaft and tighten the impeller to the specified torque Check the pump shaft for smooth rotation Install the dowel pins to the right crankcase cover Install a new O ring to the w...

Page 276: ...er cover page 3 19 Front lower cover page 3 20 Disconnect the fan motor 2P Brown connector Disconnect the water hose from upper side of the radiator Disconnect the water hoses from the lower side of t...

Page 277: ...e frame Fill and bleed the cooling system page 7 6 DISASSEMBLY Remove the radiator page 7 14 Remove the bolt washers and fan motor shroud assembly Remove the wire band from the shroud Remove the screw...

Page 278: ...fied torque Install the fan motor assembly to the shroud and tighten the screws to the specified torque Route the fan motor wire to the hook of the shroud RADIATOR 1 0 N m 0 1 kgf m 0 7 lbf ft COOLING...

Page 279: ...th recommended coolant to the upper level line FAN CONTROL RELAY INSPECTION Remove the luggage lower box page 3 16 Remove the fuse relay box cover page 3 17 Turn the ignition switch OFF Remove the fan...

Page 280: ...MEMO maxiscooter club ru...

Page 281: ...8 1 8 8 ENGINE REMOVAL INSTALLATION COMPONENT LOCATION 8 2 SERVICE INFORMATION 8 3 ENGINE REMOVAL 8 4 ENGINE INSTALLATION 8 9 maxiscooter club ru...

Page 282: ...E REMOVAL INSTALLATION 8 2 ENGINE REMOVAL INSTALLATION COMPONENT LOCATION NSS250A shown 59 N m 6 0 kgf m 44 lbf ft NSS250S NSS250S 39 N m 4 0 kgf m 29 lbf ft 30 N m 3 1 kgf m 22 lbf ft maxiscooter clu...

Page 283: ...13 9 The following components require engine removal for service Crankcase Crankshaft Balancer page 14 5 SPECIFICATION TORQUE VALUES ITEM SPECIFICATIONS Engine dry weight 48 3 kg 106 5 lbs Engine oil...

Page 284: ...the brake hose Remove the bolts and rear brake caliper Remove the adjusting nut joint pin and then pull the parking brake cable out from the holder of the swingarm Loosen the hose band screw and disc...

Page 285: ...O2 sensor 1P Black connectors Remove the bolt and fuel hose stay Disconnect the following Sensor unit 5P Black connector IACV 4P Black connector ECT sensor 3P Gray connector Disconnect the ratio contr...

Page 286: ...llowing Bolt water hose clamp Bolt spark plug wire clamp Spark plug cap Remove the rear shock absorber lower mounting bolts Loosen the tension rod nut Remove the bolts bolt washer and left step stay B...

Page 287: ...support to ease of engine hanger bracket bolt removal Remove the nut washer and pull out engine hanger bolt Remove the engine from the frame Remove the nut and tension rod Remove the collar Remove th...

Page 288: ...ger bracket Check the engine hanger bracket bushings for wear deterioration or damage Check the tension rod bushings for wear deteriora tion or damage NUTS BOLTS ENGINE HANGER BRACKET ENGINE HANGER BR...

Page 289: ...s Apply 0 50 0 70 g 0 018 0 025 oz of molybde num disulfide paste to the center groove of the engine mounting bushings and install them Loosely install the engine hangar bracket bolts and nuts 59 N m...

Page 290: ...jack or other adjustable support to ease of engine hanger bracket bolt installation Set the engine to the frame and install the engine mounting bolt Loosely install the washer and nut Loosely install...

Page 291: ...rber lower mounting bolts to the specified torque Support the scooter on its center stand Install the following Bolt spark plug wire clamp Spark plug cap Connect the water hose to the thermostat cover...

Page 292: ...ectors Install the ground cables and tighten the bolts Connect the starter motor cable and tighten the ter minal nut Cover the terminal cover Connect the rear wheel speed sensor 2P Orange connector Co...

Page 293: ...the rear brake hose clamp and tighten the bolt Set the parking brake cable clamps and tighten the bolts Install the fuel feed hose to the injector side and increase the fuel pressure page 6 73 Install...

Page 294: ...MEMO maxiscooter club ru...

Page 295: ...SSION STROKE 9 6 CYLINDER HEAD COVER REMOVAL 9 7 CAM SPROCKET CAMSHAFT ROCKER ARM REMOVAL 9 8 CYLINDER HEAD REMOVAL 9 11 CYLINDER HEAD DISASSEMBLY 9 13 VALVE GUIDE REPLACEMENT 9 15 VALVE SEAT INSPECTI...

Page 296: ...CYLINDER HEAD VALVES 9 2 CYLINDER HEAD VALVES COMPONENT LOCATION 22 N m 2 2 kgf m 16 lbf ft 38 N m 3 9 kgf m 28 lbf ft 10 N m 1 0 kgf m 7 lbf ft maxiscooter club ru...

Page 297: ...clearance IN 0 16 0 03 0 006 0 001 EX 0 22 0 03 0 009 0 001 Rocker arm Rocker arm I D IN EX 13 000 13 018 0 5118 0 5125 13 10 0 516 Rocker arm shaft O D IN EX 12 966 12 984 0 5105 0 5112 12 91 0 508...

Page 298: ...guide driver 4 3 mm 07HMD ML00101 Valve guide driver 07743 0020000 Valve guide reamer 4 5 mm 07HMH ML00101 Cutter holder 07781 0010600 Seat cutter 29 mm 45 IN 07780 0010300 Flat cutter 24 5 mm 45 EX 0...

Page 299: ...spring Uneven valve seating Cylinder head Leaking or damaged head gasket Warped or cracked cylinder head Loose spark plug Worn cylinder piston or piston rings page 10 5 Compression too high overheati...

Page 300: ...compression can be caused by Carbon deposits in the combustion chamber or on piston head POSITIONING THE PISTON AT TDC Top Dead Center ON THE COMPRESSION STROKE Remove the timing hole cap and O ring R...

Page 301: ...Apply oil to the timing hole cap threads and install it to the right crankcase cover Tighten the timing hole cap to the specified torque CYLINDER HEAD COVER REMOVAL Remove the luggage lower box page...

Page 302: ...Remove the gasket Attach a piece of wire to the cam chain to prevent it from falling into the crankcase Remove the bolts and cam sprocket Slide the rocker arms to the spring side and remove the shims...

Page 303: ...de Remove the rocker arm shafts side springs and rocker arms Be sure to mark the rocker arm shafts and rocker arms so they can be installed in their original positions INSPECTION CAM SPROCKET Check th...

Page 304: ...camshaft Check the camshaft journal for wear or damage Check each cam lobe for wear or damage Replace the camshaft assembly if necessary Check the cam lobes for scoring scratches or evi dence of insu...

Page 305: ...IDE SPRING Measure the free length of the side spring CYLINDER HEAD REMOVAL If the O2 sensor cap is disconnected replace the O2 sensor cord with a new one Drain the coolant from the system page 7 7 Re...

Page 306: ...inder head 6 mm bolts Remove the cylinder head 9 mm bolt washers Remove the cylinder head Do not strike the cylinder head too hard and do not damage the mating surface with a any tool used for leverag...

Page 307: ...alve spring seat INSPECTION CYLINDER HEAD Avoid damaging the mating and valve seat surfaces Remove the carbon deposits from the combustion chamber and clean off the head gasket surface Check the spark...

Page 308: ...each valve stem O D and record it Use cutting oil on the reamer during this operation Take care not to tilt or lean the reamer in the guide while reaming Ream the valve guide to remove any carbon buil...

Page 309: ...ing supply stores to be sure the cylinder head is heated to the proper tem perature Support the cylinder head and drive the valve guides out of the cylinder head from the combus tion chamber side Take...

Page 310: ...ping tool without rotating the valve to check for proper valve seat contact Remove the valve and inspect the valve seat face The valves cannot be ground If the valve face is burned or badly worn or if...

Page 311: ...y Valve seat cutters grinders or equivalent valve seat refacing equipment is recommended to correct worn valve seats Follow the refacing manufacture s operating instructions If the contact area is too...

Page 312: ...seat to the proper width Make sure that all pitting and irregularities are removed TOOLS Seat cutter 29 mm 45 IN 07780 0010300 Seat cutter 24 5 mm 45 EX 07780 0010100 Cutter holder 07781 0010600 ROUGH...

Page 313: ...valve and recheck the seat con tact CYLINDER HEAD ASSEMBLY Blow through the oil passage in the cylinder head with compressed air Apply oil to the inner surface of new valve stem seals Install the spri...

Page 314: ...s shown to seat the cotters firmly Install the following Cylinder head page 9 20 O2 sensor page 6 107 Thermostat page 7 10 Spark plug page 4 7 ECT sensor page 6 92 CYLINDER HEAD INSTALLATION Be carefu...

Page 315: ...ross pat tern in two or three steps to the specified torque Tighten the cylinder head 6 mm bolts Tighten the cylinder bolts Connect the water hose to the cylinder head Coat new O rings with oil and in...

Page 316: ...exchange the intake and exhaust rocker arm shafts Apply molybdenum oil solution to the rocker arm shaft sliding surface and rocker arm inner surface boss rolling surface and slipper surface Clean the...

Page 317: ...ocker arms to the spring side and install the shims in their original locations on the valve retainer CAM SPROCKET INSTALLATION Apply oil to the cam chain sprocket teeth and cam chain whole surface Tu...

Page 318: ...new gasket to the cam chain tensioner lifter Install the cam chain tensioner lifter by aligning its cut out with the cut out of the cylinder Install and tighten the bolts securely Install the spring...

Page 319: ...of the cylinder head cover Apply liquid sealant Three Bond 1211 or equiva lent to the cylinder head cover semi circular cut out as shown Install the cylinder head cover to the cylinder head The UP mar...

Page 320: ...ll the following Bolt spark plug wire clamp Bolt water hose clamp Install the spark plug cap by aligning its hole with the tab of the cylinder head cover Install the luggage lower box page 3 16 TORQUE...

Page 321: ...10 1 10 10 CYLINDER PISTON COMPONENT LOCATION 10 2 SERVICE INFORMATION 10 3 TROUBLESHOOTING 10 3 CYLINDER PISTON REMOVAL 10 4 CYLINDER PISTON INSTALLATION 10 7 maxiscooter club ru...

Page 322: ...CYLINDER PISTON 10 2 CYLINDER PISTON COMPONENT LOCATION maxiscooter club ru...

Page 323: ...der head valve problem page 9 13 Abnormal noise Worn piston pin or piston pin hole Worn connecting rod small end Worn cylinder piston or piston rings ITEM STANDARD SERVICE LIMIT Cylinder I D 68 000 68...

Page 324: ...nder page 10 4 Remove the piston pin clips with pliers Push the piston pin out of the piston and connecting rod and then remove the piston Do not damage the piston rings by spreading the ends too far...

Page 325: ...and measure the ring to groove clearance Insert each piston ring into the bottom of the cylin der squarely using the piston crown Measure the ring end gap PISTON PISTON PIN Measure the piston O D at...

Page 326: ...Measure the cylinder I D in the X and Y axes at three levels Take the maximum reading to determine the cylin der wear Calculate the taper and out of round at three levels in the X and Y axes Take the...

Page 327: ...ely in the piston ring grooves PISTON INSTALLATION Place a clean shop towel over the crankcase to pre vent any gasket material and the piston pin clips from falling into the crankcase Clean any gasket...

Page 328: ...g sprocket Apply oil to the cylinder inner surface piston outer surface and the piston ring whole surface Route the cam chain through the cylinder and install the cylinder over the piston while compre...

Page 329: ...EY DRIVEN PULLEY CLUTCH COMPONENT LOCATION 11 2 SERVICE INFORMATION 11 4 TROUBLESHOOTING 11 6 LEFT CRANKCASE COVER 11 7 DRIVE PULLEY NSS250S 11 11 DRIVE PULLEY NSS250A 11 18 CLUTCH DRIVEN PULLEY 11 27...

Page 330: ...DRIVE PULLEY DRIVEN PULLEY CLUTCH 11 2 DRIVE PULLEY DRIVEN PULLEY CLUTCH COMPONENT LOCATION NSS250S 83 N m 8 5 kgf m 61 lbf ft 79 N m 8 1 kgf m 58 lbf ft 10 N m 1 0 kgf m 7 lbf ft maxiscooter club ru...

Page 331: ...DRIVE PULLEY DRIVEN PULLEY CLUTCH 11 3 NSS250A 83 N m 8 5 kgf m 61 lbf ft 79 N m 8 1 kgf m 58 lbf ft 10 N m 1 0 kgf m 7 lbf ft maxiscooter club ru...

Page 332: ...val installation page 24 60 SPECIFICATIONS Unit mm in TORQUE VALUES ITEM STANDARD SERVICE LIMIT Drive belt width 26 5 1 04 25 5 1 00 Movable drive pulley face NSS250S Bushing I D 30 055 30 075 1 1833...

Page 333: ...sal holder 07725 0030000 Remover weight 07741 0010201 Bearing remover handle 07936 3710100 Bearing remover set 20 mm 07936 3710600 Bearing remover set 25 mm 07936 ZV10100 Bearing remover set 30 mm 079...

Page 334: ...ve pulley face position Honda S Matic System problem Poor performance at high speed or lack of power Worn drive belt Weak driven face spring NSS250S Worn weight rollers Contaminated pulley faces NSS25...

Page 335: ...cover Unhook the wires from the clamps Unhook the rear wheel speed sensor wire from the clamp Remove the bolts in a crisscross pattern in two or three steps Remove the left crankcase cover Remove the...

Page 336: ...r LEFT CRANKSHAFT BEARING REPLACEMENT Remove the element of the belt case air cleaner page 4 15 Remove the snap ring Remove the left crankshaft bearing from the left crankcase cover using special tool...

Page 337: ...rankshaft bearing to the left crankcase cover using special tools INSTALLATION Route the wires properly page 1 21 Check the rubber seal for deterioration or damage replace it if necessary Clean the ru...

Page 338: ...e left crankcase cover and then remove it Check the hatched areas of the crankshaft collar drive shaft collar and bearings as shown in the illus tration for adhesion of the molybdenum disulfide paste...

Page 339: ...que Install the left floor step page 3 12 Install the left side rear cover page 4 15 DRIVE PULLEY NSS250S REMOVAL Remove the left crankcase cover page 11 7 Hold the drive pulley face with a special to...

Page 340: ...the movable drive pulley face drive face boss ramp plate assembly DISASSEMBLY Remove the drive pulley face boss from the mov able drive pulley face ramp plate assembly DRIVE PULLEY FACE DRIVE BELT DR...

Page 341: ...ght rollers from the movable drive pulley face INSPECTION DRIVE BELT Check the drive belt for cracks separation or abnor mal or excessive wear Measure the drive belt width Replace the drive belt if ne...

Page 342: ...e the weight roller O D MOVABLE DRIVE PULLEY FACE Measure the movable drive pulley face bushing I D Check the drive pulley face boss for wear or dam age Measure the drive pulley face boss O D SLIDE PI...

Page 343: ...ive pulley face in order to prevent belt slippage Do not apply grease to the movable drive pulley face and weight rollers Install the weight rollers into the movable drive pul ley face WEIGHT ROLLER S...

Page 344: ...ble drive pulley dust seal lips Install the dust seal to the movable drive pulley face Install the drive pulley face boss to the movable drive pulley face INSTALLATION Install the movable drive face a...

Page 345: ...e collar with 0 10 g 0 004 oz of molybdenum disulfide paste Apply oil to the drive face bolt threads and sealing washer Hold the drive pulley face with the special tool and install the drive face bolt...

Page 346: ...lt washer and collar Remove the drive pulley face When the drive belt is replaced perform the Honda S Matic System initial setting procedure page 24 61 Remove the drive belt and drive pulley face boss...

Page 347: ...ss wear or dam age Replace the slide pieces if necessary REDUCTION GEAR B Check the reduction gear B for wear or damage Replace the reduction gear B if necessary DRIVE PULLEY FACE BOSS A Measure the d...

Page 348: ...oothly SCREW HOLDER BEARING INSPECTION REPLACEMENT Turn the inner race of the holder bearing with your finger The bearing should turn smoothly and quietly Also check that the bearing outer race fits t...

Page 349: ...easily spin in the groove Install the screw holder and socket bolts Tighten the socket bolts to the specified torque DISASSEMBLY INSPECTION Remove the movable drive face spline collar and oil seal fr...

Page 350: ...the O ring from the screw gear Remove the socket bolt and stopper plate Remove the screw gear by turning it counterclock wise Remove the movable drive pulley dust seal from the screw gear SOCKET BOLTS...

Page 351: ...e pulley assembly if drive pulley face boss B is out of service limit ASSEMBLY SOCKET BOLTS DRIVE PULLEY FACE BOSS B STOPPER ARM O RING OIL SEAL SERVICE LIMIT O D 34 95 mm 1 376 in SPLINE COLLAR BOSS...

Page 352: ...d install it to the screw gear as shown Fill the screw gear threads with 4 0 5 0 g 0 14 0 18 oz of the molybdenum disulfide paste and install it to the movable drive pulley face assembly Install the s...

Page 353: ...ide paste to the movable drive face spline col lar teeth Install the spline collar to the movable drive pulley face assembly INSTALLATION Movable drive pulley face is in the most squeezed position whe...

Page 354: ...elt onto the movable drive pulley face assembly Install the drive pulley face by aligning the splines Coat new O rings with oil and install them to the grooves of the collar Fill the grooves of the co...

Page 355: ...ve the left crankcase cover page 11 7 Remove the drive pulley face NSS250S page 11 11 NSS250A page 11 18 Hold the clutch outer with a special tool and loosen the clutch outer nut Remove the special to...

Page 356: ...r gradually and disassemble the following Clutch assembly Seal collar Driven pulley face spring Spring seat Spring guide collar Driven pulley assembly CLUTCH DISASSEMBLY Remove the E clips and side pl...

Page 357: ...s are replaced always replace them as a set Remove the damper rubbers from the drive plate DRIVEN PULLEY DISASSEMBLY Remove the seal collar Remove the guide roller pins and guide rollers Remove the dr...

Page 358: ...and ball bearing Pack new ball bearing cavities with grease Install the ball bearing into the driven face squarely with the sealed side facing down until it is fully seated OIL SEALS O RINGS TOOLS Bea...

Page 359: ...new needle nearing Install the needle bearing into the driven face squarely with the marked side facing up as shown INSPECTION CLUTCH OUTER Check the clutch outer for wear or damage Measure the clutch...

Page 360: ...n pulley face for scratches scoring or damage Measure the driven pulley face boss O D MOVABLE DRIVEN PULLEY FACE Check the movable driven pulley face for scratches scoring or damage Check the guide gr...

Page 361: ...PULLEY ASSEMBLY Clean the driven faces thoroughly Apply grease to new oil seal lips and install them into the movable driven pulley face Coat new O rings with oil and install them into grooves in the...

Page 362: ...rease to the driven face guide grooves of the movable driven pulley face Install the seal collar CLUTCH ASSEMBLY Install the damper rubbers onto the pivot pins on the drive plate Install the clutch sh...

Page 363: ...ng the bosses with the holes in the clutch Hold the spring compressor in a vice Install the clutch driven pulley nut Tighten the clutch driven pulley nut using a special tool to the specified torque R...

Page 364: ...ulley face Install the clutch driven pulley assembly onto the drive shaft and the drive belt onto the drive pulley face Clean any oil and grease from the clutch outer inner surface Install the clutch...

Page 365: ...ol and tighten the clutch outer nut to the specified torque Install the drive pulley face NSS250S page 11 11 NSS250A page 11 18 Install the left crankcase cover page 11 9 TOOL Flywheel holder 07725 00...

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Page 367: ...12 1 12 12 FINAL REDUCTION COMPONENT LOCATION 12 2 SERVICE INFORMATION 12 3 TROUBLESHOOTING 12 5 FINAL REDUCTION 12 6 maxiscooter club ru...

Page 368: ...FINAL REDUCTION 12 2 FINAL REDUCTION COMPONENT LOCATION NSS250A shown 24 N m 2 4 kgf m 18 lbf ft maxiscooter club ru...

Page 369: ...bearing until it is fully seated SPECIFICATIONS TORQUE VALUE ITEM SPECIFICATIONS Final reduc tion oil capac ity After draining 0 28 liter 0 30 US qt 0 25 Imp qt After disassembly 0 30 liter 0 32 US q...

Page 370: ...200 Bearing remover 20 mm 07936 3710600 Bearing remover handle 07936 3710100 Remover weight 07741 0010201 Pilot 14 mm 07746 0041200 Pilot 15 mm 07746 0040300 Pilot 20 mm 07746 0040500 Pilot 25 mm 0774...

Page 371: ...Faulty clutch driven pulley page 11 27 Abnormal noise Worn seized or chipped gears Worn or damaged final reduction bearing Oil leak Oil level too high Worn or damaged oil seal Cracked crankcase and or...

Page 372: ...page 16 5 Clutch driven pulley page 11 27 VS sensor page 22 20 Remove the rear wheel speed sensor page 18 26 Remove the collar Remove the bolts in a crisscross pattern in two or three steps Remove the...

Page 373: ...hat the bearing outer race fits tightly in the left crankcase Replace the ball bearing if the inner race does not turn smoothly quietly or if the outer race fits loosely in the left crankcase Needle b...

Page 374: ...the bearing outer race fits tightly in the final reduction case Be careful not to damage the final reduction case mating surface Remove the drive shaft using a special tool Replace the drive shaft be...

Page 375: ...t crank case NEEDLE BEARING DUST SEAL COUNTER GEAR FINAL GEAR SHAFT FINAL GEAR SHAFT BEARING 6205 2NSG OIL SEAL FINAL GEAR SHAFT BEARING 6204 NEEDLE BEARING COUNTER GEAR SHAFT DRIVE SHAFT OIL SEAL DRI...

Page 376: ...r shaft bearing using special tools Remove the final gear shaft bearing TOOLS Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Pilot 20 mm 07746 0040500 TOOLS Driver 07749 0010000 Attachment 5...

Page 377: ...0 04 in Apply oil to dust seal lips Install the final gear shaft bearing dust seal so that the depth from the final reduction case surface is 3 0 3 5 mm 0 12 0 14 in TOOLS Driver 07749 0010000 Attachm...

Page 378: ...face Install the drive shaft oil seal in the left crankcase on the drive shaft so that the depth from the left crank case surface is 0 5 1 0 mm 0 02 0 04 in using special tools Apply oil to the counte...

Page 379: ...il to the counter gear teeth and rolling area Install the counter gear and washer Install the dowel pins to the left crankcase Apply sealant TB1207B or equivalent to the mating surfaces of the final r...

Page 380: ...n two or three steps Install the collar Install the rear wheel speed sensor page 18 26 Install the following VS sensor page 22 20 Clutch driven pulley assembly page 11 36 Rear wheel page 16 13 Fill th...

Page 381: ...13 ALTERNATOR STARTER CLUTCH COMPONENT LOCATION 13 2 SERVICE INFORMATION 13 3 TROUBLESHOOTING 13 3 RIGHT CRANKCASE COVER 13 4 ALTERNATOR STATOR CKP SENSOR 13 7 FLYWHEEL STARTER CLUTCH 13 9 maxiscooter...

Page 382: ...ALTERNATOR STARTER CLUTCH 13 2 ALTERNATOR STARTER CLUTCH COMPONENT LOCATION 11 N m 1 1 kgf m 8 lbf ft 103 N m 10 5 kgf m 76 lbf ft maxiscooter club ru...

Page 383: ...ut engine does not turn Faulty starter clutch Damage starter reduction gear ITEM STANDARD SERVICE LIMIT Starter driven gear Boss O D 45 660 45 673 1 7976 1 7981 45 615 1 7959 Bushing I D 25 026 25 045...

Page 384: ...sensor wire from the clamp Remove the bolt and rear brake hose joint Remove the bolt and parking brake cable clamp Remove the clip and disconnect the water hose from the water pump cover Loosen the h...

Page 385: ...the oil joint collar Install a new O ring to the water joint collar Install the water joint collar and oil joint collar Install the dowel pins and a new gasket to the crank case Align the oil pump dr...

Page 386: ...Install the bolts with the clamp and tighten the bolts in a crisscross pattern in two or three steps Install the bolt washers to the air cleaner housing and tighten them to the specified torque Connec...

Page 387: ...page 3 33 Right floor skirt page 3 9 Right body cover page 3 11 Fill the crankcase with oil page 4 11 Fill and bleed the cooling system page 7 6 ALTERNATOR STATOR CKP SENSOR REMOVAL Remove the right c...

Page 388: ...NSTALLATION Install the stator and bolts Tighten the bolts securely Route the alternator CKP sensor wire and install the wire band to the stay BOLT STATOR CKP SENSOR WIRE GROMMET BOLTS STATOR BOLTS WI...

Page 389: ...OVAL Remove the right crankcase cover page 13 4 Remove the bolt and starter driven gear guide Hold the flywheel with a special tool and loosen the flywheel bolt Remove the special tool bolt and washer...

Page 390: ...e groove of the crankshaft DISASSEMBLY Check the operation of the sprag clutch by turning the driven gear You should be able to turn the driven gear clock wise smoothly but the gear should not turn co...

Page 391: ...e the starter driven gear boss O D Measure the starter driven gear bushing I D Check the starter clutch outer and sprag clutch for abnormal wear or damage Measure the starter clutch outer I D TOOL Fly...

Page 392: ...h by aligning the flange of the sprag clutch with the groove of the clutch outer Install the sprag clutch starter clutch outer onto the flywheel STARTER DRIVEN GEAR CLUTCH OUTER SPRAG CLUTCH FLYWHEEL...

Page 393: ...ar into the starter clutch on the flywheel while turning it clockwise Check that the starter driven gear turns clockwise smoothly and does not turn counterclockwise INSTALLATION Apply molybdenum oil s...

Page 394: ...and tighten the flywheel bolt to the specified torque Clean the starter driven gear guide bolt threads Apply locking agent to the bolt threads coating width 6 5 1 0 mm 0 26 0 04 in from the tip of exc...

Page 395: ...LANCER COMPONENT LOCATION 14 2 SERVICE INFORMATION 14 3 TROUBLESHOOTING 14 4 CRANKCASE SEPARATION 14 5 CRANKSHAFT 14 7 MAIN JOURNAL BEARING 14 11 CRANKPIN BEARING 14 16 BALANCER GEAR 14 18 CRANKCASE A...

Page 396: ...CRANKCASE CRANKSHAFT BALANCER 14 2 CRANKCASE CRANKSHAFT BALANCER COMPONENT LOCATION 12 N m 1 2 kgf m 9 lbf ft 33 N m 3 4 kgf m 24 lbf ft maxiscooter club ru...

Page 397: ...ankshaft be sure to use the special tools position the special tools against the bearing inner race and pull the crankshaft into the bearing until it is fully seated Prior to assembling the crankcase...

Page 398: ...connecting rod big end bearing Worn or damaged balancer shaft bearing Improperly installed balancer Excessive crankshaft runout Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Attachment 62...

Page 399: ...nd center stand Remove the bolt and cam chain tensioner from the crankcase Remove the cam chain from the timing sprocket Remove the oil pump drive chain from the timing sprocket Loosen the bolts in a...

Page 400: ...e 14 7 Oil pressure relief valve page 5 7 Reed valve page 5 8 Remove the balancer gear bearing using special tools RIGHT CRANKCASE LEFT CRANKCASE OIL JOINT COLLARS O RINGS BALANCER GEAR WATER JOINT CO...

Page 401: ...Remove the crankshaft from the left crankcase Remove the snap ring and oil seal from the left crankcase TOOLS Driver 07749 0010000 Attachment 42 x 47 mm 07746 0010300 Pilot 15 mm 07746 0040300 LEFT C...

Page 402: ...ee steps and remove the nuts bearing cap and connecting rod Check the journal of the crankshaft for discoloration scratch or damage Set the crankshaft on a stand or V blocks to the main journals as sh...

Page 403: ...gs by aligning the bearing tabs with the connecting rod grooves and bearing cap Install the connecting rod and cap on the crankshaft by aligning the I D code on the rod and cap Face the oil jet of the...

Page 404: ...reuse the snap ring which could easily spin in the groove Apply grease to the oil seal lips and outer surface Apply molybdenum oil solution to the main journal bearing mating surfaces of the crankshaf...

Page 405: ...ex mark Clean off any oil from the crankshaft main journals Measure and record the crankshaft main journal O D Calculate the main journal bearing I D to crankshaft main journal O D clearance main jour...

Page 406: ...n Install and tighten the right left crankcase socket bolts to the specified torque with new sealing washer BEARING SELECTION Depending upon the results of the measurements page 14 11 there are four p...

Page 407: ...13 Record the main journal O D code number Letters 1 2 or 3 on each crank weight is the main journal O D code Cross reference the crankshaft and crankcase codes to determine the replacement bearing co...

Page 408: ...743 in BEARING SUPPORT I D 45 000 45 006 mm 1 7717 1 7719 in D Green C Brown B Black 45 006 45 012 mm 1 7719 1 7721 in C Brown B Black A Blue 45 012 45 024 mm 1 7721 1 7726 in B Black A Blue A Blue 45...

Page 409: ...ting the bearing edge in the crankcase main journal Align the mating line of the bearings with the index mark on the crankcase as shown Set the hydraulic press and special tools as shown BEARING THICK...

Page 410: ...CRANKPIN BEARING BEARING INSPECTION Disassemble the connecting rod page 14 8 Check the crankpin bearings for abnormal wear damage or peeling and replace them if necessary Assemble the connecting rod...

Page 411: ...e 14 17 Assemble the connecting rod page 14 9 BEARING SELECTION Disassemble the connecting rod page 14 8 Record the connecting rod I D code number Number 1 2 or 3 on the connecting rod is the con nect...

Page 412: ...the balancer gear from the left crankcase DISASSEMBLY INSPECTION Remove the snap ring and washer CONNECTING ROD I D CODE 1 2 3 39 000 39 006 mm 1 5354 1 5357 in 39 006 39 012 mm 1 5357 1 5359 in 39 01...

Page 413: ...he balancer gear bearing with your finger The balancer gear bearing should turn smoothly and quietly Also check that the balancer gear bearing outer race fits tightly in the crankcase Replace the bala...

Page 414: ...the balancer shaft sub gear and balancer gear springs Install the washer and snap ring into the balancer gear shaft groove Check that the snap ring is seated in the groove Do not reuse the snap ring w...

Page 415: ...r other damage Dress any roughness or irregularities with an oil stone Apply sealant TB1207B or equivalent to the right and left crankcase mating surfaces Clean the disassembled parts with oil Apply o...

Page 416: ...hain onto the timing sprocket Install the cam chain tensioner and bolt Tighten the cam chain tensioner bolt to the speci fied torque Apply grease to the main stand shaft sliding sur face Fill the main...

Page 417: ...E CRANKSHAFT BALANCER 14 23 Install the center stand springs Install the removed parts in the reverse order of removal Install the engine to the frame page 8 9 RIGHT SIDE LEFT SIDE SPRINGS maxiscooter...

Page 418: ...MEMO maxiscooter club ru...

Page 419: ...5 FRONT WHEEL SUSPENSION STEERING COMPONENT LOCATION 15 2 SERVICE INFORMATION 15 3 TROUBLESHOOTING 15 5 HANDLEBAR 15 6 HANDLEBAR POST 15 11 FRONT WHEEL 15 13 FORK 15 18 STEERING STEM 15 25 maxiscooter...

Page 420: ...COMPONENT LOCATION NSS250A shown 27 N m 2 8 kgf m 20 lbf ft 39 N m 4 0 kgf m 29 lbf ft 12 N m 1 2 kgf m 9 lbf ft 30 N m 3 1 kgf m 22 lbf ft 69 N m 7 0 kgf m 51 lbf ft 22 N m 2 2 kgf m 16 lbf ft 128 N...

Page 421: ...les Never use an air hose or brush to clean brake assemblies Use and OSHA approved vacuum cleaner ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 1 5 0 06 Cold tire pressure Driver only 175 kPa 1...

Page 422: ...07746 0050600 Attachment 42 x 47 mm 07746 0010300 Attachment 52 x 55 mm 07746 0010400 Inner driver 35 mm 07746 0030400 Pilot 20 mm 07746 0040500 Fork seal driver body 07747 0010100 Fork seal driver at...

Page 423: ...ushings page 8 4 Front wheel wobbles Bent rim Worn or damaged front wheel bearings Axle fastener not tightened properly Unbalanced front wheel and tire Faulty tire Front wheel turns hard Faulty front...

Page 424: ...master cylinder Remove the screws and left handlebar switch hous ing When replacing the handlebar grip remove the screw and left handlebar weight Remove the left handlebar grip LEFT REAR VIEW MIRROR W...

Page 425: ...he bolts holder and right master cylinder Remove the screw and right handlebar weight Remove the screws and right handlebar switch housing RIGHT REAR VIEW MIRROR WIRE BAND Keep the right master cylind...

Page 426: ...nt to the inside of the handlebar grip and to the clean surfaces of the left handlebar Wait 3 5 minutes and install the grips Rotate the grips for even application of the adhe sive Apply 0 10 0 20 g 0...

Page 427: ...the front side socket bolts first and then tighten the rear side socket bolts to the specified torque Align the locating pin of the right handlebar switch housing with the hole on the handlebar Insta...

Page 428: ...o the specified torque When removing the handlebar weight install the handlebar weight Install a new screw and tighten it securely Install the left handlebar switch housing by aligning the locating pi...

Page 429: ...left rearview mirror and tighten the lock nut to the specified torque HANDLEBAR POST REMOVAL Remove the following Handlebar page 15 6 Handlebar post cover page 3 20 Remove the socket bolts washers and...

Page 430: ...the lower holders Remove the bolts and handlebar post from the steering stem Discard the bolts Remove the rubber seal Check the condition of the rubber seal replace it if necessary INSTALLATION Instal...

Page 431: ...ar handle cover Install the front handle cover socket bolts and washers Remove the following Handlebar post cover page 3 20 Handlebar page 15 8 FRONT WHEEL REMOVAL Loosen the right axle holder bolt Lo...

Page 432: ...ual runout is 1 2 the total indicator reading WHEEL Check the rim runout by placing the wheel in a truing stand Spin the wheel slowly and read the runout using a dial indicator Actual runout is 1 2 th...

Page 433: ...tire and valve stem of the rim within 50 mm 2 0 in Remove the dust seals from the wheel Mount the wheel tire and brake disc assembly in an inspection stand Spin the wheel allow it to stop and mark the...

Page 434: ...move the distance collar and drive the other bear ing out ASSEMBLY DUST SEAL Replace the wheel bearings in pairs Do not reuse the old bearings TOOLS Bearing remover shaft 07GGD 0010100 Bearing remover...

Page 435: ...y grease to a new dust seal lips Install the dust seal into right side of the wheel hub until it is flush with the wheel hub Install the brake disc on the wheel hub with the stamp facing out Install a...

Page 436: ...stall the front axle holder bolt and tighten it to the specified torque NSS250A After installing the front wheel check the clearance air gap between the sensor and pulser ring page 18 24 FORK REMOVAL...

Page 437: ...t jaws or shop towel Loosen the fork socket bolt slightly but do not remove yet The fork cap bolt is under spring pressure use care when loosening it Remove the fork cap bolt Remove the fork spring fo...

Page 438: ...the socket bolt and sealing washer Do not remove the fork piston ring unless it is necessary to replace it with a new one Remove the fork piston and rebound spring from the fork pipe Using quick succ...

Page 439: ...the back up ring and guide bushing from the bottom case INSPECTION FORK SPRING Check the fork spring for fatigue or damage Measure the fork spring free length FORK PIPE BOTTOM CASE Check the fork pip...

Page 440: ...any dis tortion at the points shown To prevent loss of tension do not open the slider bushing more than necessary When replacing the fork pipe bushing remove the fork pipe bushing by opening the bushi...

Page 441: ...m the fork pipe bushing mating surface being careful not to peel off the coating Be careful not to damage the slider bushing coat ing PISTON RING O RING FORK PISTON FORK SPRING DUST SEAL STOPPER RING...

Page 442: ...ng groove appear using special tools Install the stopper ring into the groove in the bot tom case being careful not to scratch the fork pipe Coat a new dust seal lips with fork fluid and install it in...

Page 443: ...the upper lower fork mounting bolts to the specified torque Install the front brake caliper to the fork leg and tighten new mounting bolts to the specified torque Install the brake hose clamp and tig...

Page 444: ...the steering stem lock nut using a special tool Hold the steering stem and remove the steering stem adjusting nut Remove the upper dust seal inner race and upper ball bearing TOOLS Socket wrench 07916...

Page 445: ...a new lower outer race into the head pipe using special tools LOWER BALL BEARING STEERING STEM TOOLS Ball race remover 07YAC 0010102 Ball race remover shaft 07JAC PH80200 Remover weight 07741 0010201...

Page 446: ...age the stem Remove the lower dust seal Apply specified grease page 1 20 to a new lower dust seal lips then Install a new dust seal Install a new lower bearing inner race using a spe cial tool and hyd...

Page 447: ...ge 1 20 to the upper bearing and both side of the upper bearing race Install the upper bearing upper bearing inner race and dust seal onto the stem EXTREME PRESSURE GREASE BEARING BEARING RACE DUST SE...

Page 448: ...Tighten the steering stem adjusting nut to the speci fied torque Install the lock washer to the steering stem by align ing the tab of the lock washer with the groove of the steering stem TOOL Pin span...

Page 449: ...raise the front wheel Make sure the steering stem moves smoothly with out play or binding Install the brake hose clamp and bolt and tighten the bolt Install the following Handlebar post page 15 11 Inn...

Page 450: ...MEMO maxiscooter club ru...

Page 451: ...16 REAR WHEEL PARKING BRAKE SUSPENSION COMPONENT LOCATION 16 2 SERVICE INFORMATION 16 3 TROUBLESHOOTING 16 4 REAR WHEEL SWINGARM 16 5 PARKING BRAKE LEVER 16 15 REAR SHOCK ABSORBER 16 16 maxiscooter c...

Page 452: ...2 REAR WHEEL PARKING BRAKE SUSPENSION COMPONENT LOCATION 49 N m 5 0 kgf m 36 lbf ft 118 N m 12 0 kgf m 87 lbf ft 39 N m 4 0 kgf m 29 lbf ft 30 N m 3 1 kgf m 22 lbf ft 11 N m 1 1 kgf m 8 lbf ft 39 N m...

Page 453: ...t inhalation of brake shoe dust regardless of material composition could be hazardous to your health Avoid breathing dust particles Never use an air hose or brush to clean brake assemblies Use an OSHA...

Page 454: ...from damper unit Low tire pressure Stiff suspension Bent damper rod Worn or damaged engine mount bushings High tire pressure Rear suspension noisy Weak rear suspension bushings Faulty shock absorber L...

Page 455: ...rake caliper from the swingarm Support the brake caliper so that it does not hang from the brake hose Do not twist the brake hose Do not reuse the mounting bolts Remove the bolt washers Lift the rear...

Page 456: ...shock absorber lower mounting bolt Remove the rear axle nut Remove the mounting bolts and swingarm Remove the parking brake drum Remove the rear wheel MOUNTING BOLT SWINGARM MOUNTING BOLTS SWINGARM A...

Page 457: ...um if it is below a ser vice limit Measure the thickness of each shoe Replace the parking brake shoes if it is below a ser vice limit page 16 8 WHEEL DISASSEMBLY NSS250A Remove the rear pulser ring pa...

Page 458: ...set Mark the brake shoes to ensure that they are rein stalled on their original location Remove the brake shoes and springs by spreading the brake shoes Remove the bolt parking brake arm and return sp...

Page 459: ...ing with your finger The bearing should turn smoothly and quietly Also check that the bearing outer race fits tightly in the swingarm Replace the bearing if the inner race does not turn smoothly and q...

Page 460: ...all the snap ring into the groove of the swing arm securely Check that the snap ring is seated in the groove Do not reuse the snap ring which could easily spin in the groove Apply grease to a new dust...

Page 461: ...e parking brake anchor pin brake cam sliding surface and install the brake cam 30 N m 3 1 kgf m 22 lbf ft SHOE SPRINGS BRAKE SHOES BRAKE CAM SNAP RING BEARING COLLAR BRAKE ARM RETURN SPRING DUST SEAL...

Page 462: ...ghten it to the specified torque If the brake shoes are reused they must be placed back in their original locations Install the shoe springs onto the brake shoes as shown Install the brake shoes onto...

Page 463: ...inal gear shaft 3 mm ground with 0 030 0 040 g 0 0011 0 0014 oz minimum of grease Apply grease to the final gear shaft 17 bearing roll ing area Install the swingarm and tighten the swingarm mounting b...

Page 464: ...mounting bolts to the specified torque Adjust the parking brake lever page 4 20 then apply the parking brake Tighten the rear axle nut to the specified torque NSS250A After installing the rear wheel...

Page 465: ...n the reverse order of removal PARKING BRAKE CABLE Remove the front side cover page 3 21 Loosen the lock nut and disconnect the parking brake cable from the parking brake lever link Remove the adjusti...

Page 466: ...g bolts and shock absorber INSPECTION Check the dumper unit for leakage or other damage Check the upper joint bushings for wear or damage Replace the shock absorber assembly if necessary INSTALLATION...

Page 467: ...ERVICE INFORMATION 17 4 TROUBLESHOOTING 17 6 BRAKE FLUID REPLACEMENT AIR BLEEDING 17 7 BRAKE PAD DISC 17 14 RIGHT MASTER CYLINDER 17 17 LEFT MASTER CYLINDER 17 22 DELAY VALVE 17 27 FRONT BRAKE CALIPER...

Page 468: ...ULIC BRAKE 17 2 HYDRAULIC BRAKE COMPONENT LOCATION FRONT 34 N m 3 5 kgf m 25 lbf ft 34 N m 3 5 kgf m 25 lbf ft NSS250A 12 N m 1 2 kgf m 9 lbf ft 30 N m 3 1 kgf m 22 lbf ft NSS250A shown maxiscooter cl...

Page 469: ...YDRAULIC BRAKE 17 3 REAR 34 N m 3 5 kgf m 25 lbf ft 12 N m 1 2 kgf m 9 lbf ft 30 N m 3 1 kgf m 22 lbf ft 34 N m 3 5 kgf m 25 lbf ft 34 N m 3 5 kgf m 25 lbf ft NSS250A NSS250A shown maxiscooter club ru...

Page 470: ...ifferent types of fluid they may not be compatible Once the hydraulic system has been opened or if the brake feels spongy the system must be bled Always check brake operation before riding the scooter...

Page 471: ...rew 1 2 N m 0 1 kgf m 0 9 lbf ft Brake light switch screw 1 2 N m 0 1 kgf m 0 9 lbf ft Brake lever pivot nut 6 N m 0 6 kgf m 4 4 lbf ft Brake lever pivot bolt 1 0 N m 0 1 kgf m 0 7 lbf ft Front calipe...

Page 472: ...ake lever Brake lever hard Clogged restricted brake system Sticking worn caliper piston Caliper not sliding properly Worn caliper piston seal Sticking worn master cylinder piston Bent brake lever Faul...

Page 473: ...rt the scooter on its center stand and turn the handlebar until the reservoir is parallel to the ground Remove the screws reservoir cap diaphragm plate and diaphragm from the right master cylinder Con...

Page 474: ...ed hose to the front brake caliper lower bleed valve Loosen the bleed valve and pump the left brake lever until no more fluid flows out of the bleed valve Tighten the front brake caliper lower bleed v...

Page 475: ...DOT 4 brake fluid from a sealed con tainer Do not mix different types of fluid There are not compatible NSS250S DELAY VALVE FRONT BRAKE CALIPER REAR BRAKE CALIPER NSS250A DELAY VALVE ABS MODULATOR LEF...

Page 476: ...ecified torque After bleeding air operate the right brake lever If it still feels spongy bleed the system again Fill the reservoir with DOT 4 brake fluid to the upper level If the brake bleeder is not...

Page 477: ...hragm plate reservoir cap and tighten the screws securely LEFT COMBINED BRAKE LINE FILLING AIR BLEEDING BRAKE FLUID FILLING Connect a commercially available brake bleeder to the lower bleed valve of t...

Page 478: ...er level Operate the left brake lever several times to bleed air from the master cylinder Connect a bleed hose to the rear brake caliper bleed valve and bleed the system as follows 1 Pump the left bra...

Page 479: ...sistance on the left combined brake lever during pumping to bleed air from the caliper This symptom is caused by the delay valve function Be sure to push the left brake lever fully in by this point Af...

Page 480: ...h the caliper pistons all the way in by pushing the caliper body inward to allow installation of new brake pads Remove the pad pin and brake pads Make sure the pad spring is installed in position Inst...

Page 481: ...s against the pads REAR Remove the muffler page 3 32 Push the caliper piston all the way in by pushing the caliper body inward to allow installation of new brake pads Remove the rear caliper mounting...

Page 482: ...pecified torque Be careful not to damage the caliper pin boot Install the caliper to the swingarm so that the disc is positioned between the pads being careful not to damage the pads Install new brake...

Page 483: ...re nor mal RIGHT MASTER CYLINDER REMOVAL Spilled fluid can damage painted plastic or rubber parts Place a rag over these parts whenever the system is serviced When removing the brake hose oil bolt cov...

Page 484: ...e master cylinder holder bolts holder and master cylinder DISASSEMBLY Remove the pivot nut pivot bolt and brake lever Remove the screw and brake light switch BRAKE HOSE OIL BOLT SEALING WASHERS BOLTS...

Page 485: ...t piston cups for fatigue or damage Measure the master cylinder piston O D ASSEMBLY TOOL Snap ring pliers 07914 SA50001 Be sure that each parts is free from the dust or dirt before reassembly SNAP RIN...

Page 486: ...l the washer and snap ring into the groove in the master cylinder Check that the snap ring is seated in the groove Do not reuse the snap ring which could easily spin in the groove Install the piston b...

Page 487: ...rst then tighten the lower bolt to the specified torque Connect the brake hose with the oil bolt and new sealing washers Set the brake hose joint onto the stopper of the master cylinder then tighten t...

Page 488: ...king out Remove the left rearview mirror page 15 6 Drain the left combined brake line hydraulic sys tem page 17 7 Disconnect the brake light switch connectors and inhibitor switch connectors Disconnec...

Page 489: ...NSPECTION Check the master cylinder for abnormal scratches Measure the master cylinder I D Check the master piston for abnormal scratches Check the piston boot piston cups for fatigue or damage Measur...

Page 490: ...fluid Install the spring onto the master piston Install the spring to the master piston end Install the spring and master piston into the master cylinder SNAP RING BOOT MASTER CYLINDER SPRING BRAKE L...

Page 491: ...ke light inhibitor switch and tighten the screws to the specified torque Fill the contact surfaces with 0 10 g 0 004 oz mini mum of silicone grease of the brake lever piston tip and brake lever pivot...

Page 492: ...e joint onto the stopper of the master cylinder then tighten the oil bolt Connect the brake light switch and inhibitor switch connectors Fill and bleed the left combined brake line hydrau lic system p...

Page 493: ...discon nect the brake hoses Remove the delay valve mounting bolts and delay valve Installation is in the reverse order of removal At installation replace the sealing washers with new ones Tighten the...

Page 494: ...e front wheel speed sensor page 18 24 Disconnect the brake hoses from the brake caliper by removing the oil bolts and sealing washers Do not reuse the caliper mounting bolts Remove the caliper mountin...

Page 495: ...ston sliding surface Remove the dust seals and piston seals Clean the seal grooves caliper cylinders and pis tons with clean brake fluid INSPECTION Check the caliper cylinder for scoring or other dam...

Page 496: ...o the seal grooves in the caliper cylinder Coat the caliper piston outer surface with clean brake fluid and install them into their original loca tions with the opening sides toward the pads DUST SEAL...

Page 497: ...ting bolts and tighten them to the specified torque Connect the brake hoses to the front brake caliper with the oil bolts and new sealing washers Set the hose joints onto the stopper and tighten the o...

Page 498: ...hose from the rear brake cali per by removing the oil bolt and sealing washers Remove the rear brake pads page 17 15 DISASSEMBLY Remove the caliper bracket from the caliper body Remove the caliper pi...

Page 499: ...age Measure the caliper cylinder I D Check the caliper piston for scoring scratches or damage Measure the caliper cylinder piston O D ASSEMBLY DUST SEAL PISTON SEAL SERVICE LIMIT 38 24 mm 1 506 in SER...

Page 500: ...amage Apply 0 4 g 0 01 oz minimum of silicone grease to the caliper bracket pin boots and install them into the caliper body and bracket Install the caliper pin into the pin boot Install the caliper b...

Page 501: ...LOCATIONS 18 5 ABS TROUBLESHOOTING INFORMATION 18 7 ABS INDICATOR PROBLEM CODE INDEX 18 10 ABS INDICATOR CIRCUIT TROUBLESHOOTING 18 12 ABS TROUBLESHOOTING 18 15 FRONT WHEEL SPEED SENSOR 18 24 FRONT P...

Page 502: ...BS SYSTEM LOCATION REAR WHEEL SPEED SENSOR LEFT MASTER CYLINDER RIGHT MASTER CYLINDER ABS MODULATOR DELAY VALVE FRONT PULSER RING FRONT WHEEL SPEED SENSOR FRONT BRAKE CALIPER REAR PULSER RING REAR BRA...

Page 503: ...VSP FR VSP 16 IGN POWER ABS 61 62 ABS 11 12 SC S 13 MOTOR GND 25 DIAG 10 9 MOTOR 8 FAIL SAFE RLY ABS 51 52 53 ABS 54 ABS 81 ABS 21 ABS 23 ABS BATTERY FUSE RELAY BOX IGNITION SWITCH ABS MOTOR FUSE ABS...

Page 504: ...ABS diagnosis system Read ABS TROUBLESHOOTING INFORMATION carefully inspect and troubleshoot the ABS system according to the Diagnostic Troubleshooting flow chart Observe each step of the procedures...

Page 505: ...ABS NSS250A 18 5 ABS CONNECTOR LOCATIONS NOTE 1 Remove the front side cover page 3 21 ABS MODULATOR 25P CONNECTOR FRONT WHEEL SPEED SENSOR 2P Blue CONNECTOR maxiscooter club ru...

Page 506: ...NSS250A 18 6 NOTE 2 Remove the luggage lower box page 3 16 NOTE 3 Remove the battery cover page 19 6 REAR WHEEL SPEED SENSOR 2P Orange CONNECTOR ABS SERVICE CHECK 3P Natural CONNECTOR maxiscooter club...

Page 507: ...le speed goes to 10 km h 6 mph approxi mately If the ABS indicator blinks because problem is detected during the pre start self diagnosis page 18 7 If the ABS indicator does not come on when the ignit...

Page 508: ...gnition switch ON again does not indicate the problem code To show the problem code again repeat the problem code retrieval procedures from the beginning Do not apply the front or rear brake during re...

Page 509: ...ld come on for 2 seconds and go off 3 Release the brake lever immediately after the ABS indicator is off The ABS indicator should come on 4 Squeeze the brake lever immediately after the ABS indicator...

Page 510: ...main fuse 5 A ABS indicator never come ON at all 18 12 ABS indicator stays ON at all 18 13 11 Front wheel speed sensor circuit malfunction Wheel speed sensor or related wires O O Stops ABS operation 1...

Page 511: ...circuit Over voltage Input voltage too high O O Stops ABS operation 71 Tire malfunction Tire size O Stops ABS operation 18 23 81 ABS control unit ABS control unit malfunction ABS modu lator O O Stops...

Page 512: ...28 Turn the ignition switch ON engine stop switch and check the ABS indicator Does the indicator come on YES Faulty ABS modulator NO GO TO STEP 3 3 Indicator Signal Line Short Circuit Inspection Turn...

Page 513: ...cuit in Brown white wire between the service check 3P Natural connector and ABS modulator NO GO TO STEP 2 2 Indicator Signal Line Short Circuit Inspection Check the continuity between the ABS modula t...

Page 514: ...emove the jumper wire from the combination meter 28P Gray connector Disconnect the ABS modulator 25P connector page 18 28 With the combination meter 28P Gray connec tor connected short the Red black w...

Page 515: ...und line page 18 22 Also check the ABS indicator cir cuit page 18 12 PROBLEM CODE 11 12 21 41 or 42 Front Wheel Speed Sensor Front Pulser Ring Front Wheel Lock The ABS indicator might blink under unus...

Page 516: ...wheel speed sensor 2P Blue connector page 18 24 Turn the ignition switch ON engine stop switch Measure the voltage at the front wheel speed sensor 2P connector of the wire side Is there battery voltag...

Page 517: ...heel Speed Sensor Replace the front wheel speed sensor with a new one page 18 24 Connect the ABS modulator 25P and front wheel speed sensor 2P Blue connectors Erase the problem code page 18 9 Test rid...

Page 518: ...he rear wheel speed sensor and pulser ring Check that there is iron or other magnetic depos its between the pulser ring slots and rear wheel speed sensor and the pulser ring slots for obstructions Che...

Page 519: ...NO Open circuit in Pink white wire Open circuit in Green red wire 6 Failure Reproduction with a New Rear Wheel Speed Sensor Replace the rear wheel speed sensor with a new one page 18 26 Connect the AB...

Page 520: ...voltage at the ABS modulator 25P connector terminals of the wire side Is the battery voltage YES GO TO STEP 3 NO GO TO STEP 2 2 Motor Power Input Line Short Circuit Inspection Check the continuity bet...

Page 521: ...tor is normal intermittent fail ure PROBLEM CODE 54 Fail safe Relay 1 Relay Power Input Voltage Inspection Disconnect the ABS modulator 25P connector page 18 28 Measure the voltage between the ABS mod...

Page 522: ...r blink 54 times YES Faulty ABS modulator NO Fail safe relay is normal intermittent failure PROBLEM CODE 61 or 62 Power Circuit 1 ABS Power Input Voltage Inspection Disconnect the ABS modulator 25P co...

Page 523: ...e indicator blink 61 or 62 times YES Faulty ABS modulator NO Power circuit is normal intermittent failure PROBLEM CODE 71 Tire Size Check the following and correct the faulty part Incorrect tire press...

Page 524: ...ound Measure the clearance air gap between the sensor and pulser ring at several points by turning the wheel slowly It must be within specification The sensor air gap cannot be adjusted If it is not w...

Page 525: ...NT PULSER RING INSPECTION Support the scooter on its center stand and raise the rear wheel off the ground Check the pulser ring for scratch or damage Replace the pulser ring if necessary REMOVAL INSTA...

Page 526: ...each installa tion part for deformation looseness and damage REMOVAL INSTALLATION Remove the following Rear wheel page 16 5 Left floor step page 3 12 Left side front cover left side rear cover page 4...

Page 527: ...y page 1 21 Install the wire bands to the left crankcase Clamp the sensor wire to the wire band Connect the rear wheel speed sensor 2P Orange connector Install the following Left side front cover left...

Page 528: ...rance air gap between the sensor and pulser ring page 18 26 ABS MODULATOR Spilled brake fluid will severely damage instrument lenses ad painted surfaces It is also harmful to some rubber parts When re...

Page 529: ...and brake pipe joints Remove the bolt and brake pipe joint Remove the joint nut and disconnect the brake pipe Remove the bolt washer BRAKE PIPES JOINT NUTS BRAKE PIPES BRAKE PIPE JOINT BRAKE PIPE JOIN...

Page 530: ...bolt washers Be careful not to bend or damage the brake pipes during ABS modulator assembly removal BOLT WASHERS MODULATOR BRAKE PIPE TO FRONT BRAKE CALIPER ABS MODULATOR BOLT WASHER BRAKE PIPE TO RIG...

Page 531: ...ect the brake pipe joints and install and tighten the bolts Be careful not to bend or damage the brake pipes Apply brake fluid to the joint nut threads Connect the brake pipes to the ABS modulator and...

Page 532: ...BS modulator 25P connector by push ing the lock lever down to connect it Fill and bleed the right and left hydraulic systems with brake fluid page 17 7 Install the inner cover page 3 27 25P CONNECTOR...

Page 533: ...ARGING SYSTEM SYSTEM LOCATION 19 2 SYSTEM DIAGRAM 19 2 SERVICE INFORMATION 19 3 TROUBLESHOOTING 19 4 BATTERY 19 6 CHARGING SYSTEM INSPECTION 19 7 ALTERNATOR CHARGING COIL 19 8 REGULATOR RECTIFIER 19 9...

Page 534: ...SYSTEM SYSTEM LOCATION NSS250A shown SYSTEM DIAGRAM REGULATOR RECTIFIER BATTERY ALTERNATOR FUSE RELAY BOX MAIN FUSE 40 A NSS250S BATTERY MAIN A FUSE 40A R W G Y Y Y REGULATOR RECTIFIER ALTERNATOR G R...

Page 535: ...of time without riding the scooter The battery will self discharge when the scooter is not in use For this reason charge the battery every two weeks to prevent sulfation from occurring When checking...

Page 536: ...and recheck the battery current leakage Is the current leakage below 1 5 mA YES Faulty regulator rectifier NO Shorted wire harness Faulty ignition switch page 23 26 5 ALTERNATOR CHARGING COIL INSPECT...

Page 537: ...e voltage and resistance at the regulator rectifier connector page 19 9 Are the results of checked voltage and resistance correct YES Faulty regulator rectifier NO Open circuit in related wire Loose o...

Page 538: ...battery band Remove the bolt and disconnect the battery nega tive cable from the battery Remove the bolt and disconnect the battery positive cable from the battery Remove the battery Install the batt...

Page 539: ...e bat tery negative terminal With the ignition switch turned OFF check for cur rent leakage When measuring current using a tester set it to a high range and then bring the range down to an appropriate...

Page 540: ...1 rpm ALTERNATOR CHARGING COIL INSPECTION Remove the right body cover page 3 11 Disconnect the alternator 3P Black connector Measure the resistance between all three Yellow wire terminals of the alte...

Page 541: ...mal and there are no loose connections at the regulator rectifier connectors replace the regulator rectifier REMOVAL INSTALLATION Remove the right body cover page 3 11 Disconnect the regulator rectifi...

Page 542: ...MEMO maxiscooter club ru...

Page 543: ...20 20 IGNITION SYSTEM SYSTEM LOCATION 20 2 SYSTEM DIAGRAM 20 2 SERVICE INFORMATION 20 3 TROUBLESHOOTING 20 4 IGNITION SYSTEM INSPECTION 20 5 IGNITION COIL 20 10 IGNITION TIMING 20 11 maxiscooter club...

Page 544: ...GN FUSE 10 A MAIN B FUSE 15 A ENGINE STOP RELAY CKP SENSOR IGNITION SWITCH ECU IGN FUSE 10 A MAIN B FUSE BATTERY ENGINE STOP RELAY ENGINE STOP SWITCH BANK ANGLE SENSOR 15 A SIDESTAND SWITCH PCM ECM CK...

Page 545: ...ery is adequately charged Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark plug Although the PCM ECM is controlling ignition timin...

Page 546: ...ircuit or loose connection in Green wire of the PCM ECM 5 An open circuit or loose connection in Yellow blue wire between the ignition coil and PCM ECM 6 Short circuit in Black white wire of the ignit...

Page 547: ...ITION COIL PRIMARY PEAK VOLTAGE Check all system connections before performing this inspection If the system is disconnected incorrect peak voltage might be measured Check that the cylinder compressio...

Page 548: ...lug is installed correctly Place the scooter on its center stand Disconnect the ECM 33P Black connector page 6 95 Connect the peak voltage adaptor to the terminals of the ECM 33P Black connector Turn...

Page 549: ...moved parts in the reverse order of removal USING THE TEST HARNESS Check all system connections before performing this inspection If the system is disconnected incorrect peak voltage might be measured...

Page 550: ...removal CKP SENSOR PEAK VOLTAGE NSS250A USING THE TEST PROBE Check all system connections before performing this inspection If the system is disconnected incorrect peak voltage might be measured Chec...

Page 551: ...emoved parts in the reverse order of removal USING THE TEST HARNESS Check all system connections before performing this inspection If the system is disconnected incorrect peak voltage might be measure...

Page 552: ...ltages measure are abnormal check each item in the troubleshooting chart page 20 4 If all items are normal the CKP sen sor is faulty See following steps for CKP sensor replacement page 13 7 Install th...

Page 553: ...s correct if the index notch on the right crankcase cover aligns between the F mark on the flywheel as shown Check that the O ring is in good condition Replace it if necessary Coat the O ring with oil...

Page 554: ...MEMO maxiscooter club ru...

Page 555: ...21 1 21 21 ELECTRIC STARTER SYSTEM LOCATION 21 2 SYSTEM DIAGRAM 21 2 SERVICE INFORMATION 21 3 TROUBLESHOOTING 21 4 STARTER MOTOR 21 6 STARTER RELAY SWITCH 21 15 maxiscooter club ru...

Page 556: ...TION SWITCH BATTERY STARTER RELAY SWITCH SIDESTAND SWITCH STARTER MOTOR NSS250S IG ST INHIBITOR SWITCH STARTER SWITCH Bl Bl Bu G R R G Y R NSS250S Bl R NSS250A Bl R Bl R Bl R G W G Bl 12P Bu STARTER R...

Page 557: ...The starter motor can be serviced with the engine in the frame When checking the starter system always follow the steps in the troubleshooting page 21 4 Refer to the following components informations...

Page 558: ...Is there CLICK YES GO TO STEP 4 NO GO TO STEP 5 4 Starter Motor Inspection Turn the ignition switch OFF Apply battery voltage to the starter motor directly and check the operation Dose the starter mot...

Page 559: ...in wires between the battery and ignition switch 7 Starter Relay Switch Continuity Inspection Remove the starter relay switch page 21 16 Check the starter relay switch for continuity page 21 16 Is th...

Page 560: ...tor Remove the left side rear cover page 4 15 Uncover the terminal cover and remove the nut and starter motor cable from the starter motor Remove the mounting bolts ground cables and starter motor Rem...

Page 561: ...over and seal ring Remove the rear cover and seal ring Remove the motor case from the armature Remove the brushes from the brush holder FRONT COVER SEAL RING REAR COVER SEAL RING ARMATURE MOTOR CASE B...

Page 562: ...Check for continuity between the positive brushes terminal bolt side and rear cover These should be no continuity Check for continuity between positive and negative brushes There should be no continu...

Page 563: ...inal stopper O ring Remove the terminal bolt positive brushes and brush holder from the rear cover Inspect the brushes for damage and measure the brush length NUT O RING TERMINAL STOPPER INSULATOR WAS...

Page 564: ...inuity Check for continuity between each individual com mutator bar and armature shaft There should be no continuity Check the dust seal for deterioration wear or dam age Turn the inner race of the st...

Page 565: ...positive brushes and termi nal bolt to the rear cover BUSHING 4 9 N m 0 5 kgf m 3 6 lbf ft O RING FRONT COVER SEAL RING MOTOR CASE SEAL RING INSULATOR WASHER NUT TERMINAL STOPPER O RING REAR COVER BR...

Page 566: ...topper Insulator Washer Install and tighten the terminal nut Install the negative brushes and screw Tighten the screw securely Install the springs to the brush holder O RING TERMINAL STOPPER INSULATOR...

Page 567: ...tab on the rear cover The coil may be damaged if the magnet pulls the armature against the case Install a new seal ring to the motor case Install the front cover to the motor case Be careful not to da...

Page 568: ...starter motor to the crankcase Install the ground cables and bolts to the starter motor Tighten the bolts securely Connect the starter motor cable and install and tighten the nut securely Cover the t...

Page 569: ...rter relay 4P connector of the wire side and ground If there is continuity when the sidestand switch is retracted the ground circuit is normal If there is no continuity when the sidestand switch is re...

Page 570: ...here should be continuity between the cable termi nals while the battery is connected and no continu ity when the battery disconnected REMOVAL INSTALLATION Remove the luggage lower box page 3 16 Remov...

Page 571: ...OMBINATION METER 22 10 SPEEDOMETER VS SENSOR 22 18 TACHOMETER 22 21 COOLANT TEMPERATURE GAUGE ECT SENSOR 22 24 EOP SWITCH 22 25 FUEL GAUGE FUEL LEVEL SENSOR 22 26 HANDLEBAR SWITCHES NSS250S 22 27 HAND...

Page 572: ...HES SYSTEM LOCATION NSS250A shown TURN SIGNAL RELAY LUGGAGE BOX LIGHT SWITCH FUEL PUMP UNIT VS SENSOR EOP SWITCH SIDESTAND SWITCH FUSE RELAY BOX HEADLIGHT RELAY Lo HEADLIGHT RELAY Hi MAIN RELAY HORN P...

Page 573: ...r turn signal removal installation page 3 22 For rear combination light removal installation page 3 23 For license light removal installation page 3 31 Route the wires and cables properly after servic...

Page 574: ...NSS250A 1 2 N m 0 1 kgf m 0 9 lbf ft Parking brake light switch screw 1 47 N m 0 1 kgf m 1 1 lbf ft Front turn signal light screw 1 0 N m 0 1 kgf m 0 7 lbf ft Headlight screw 1 1 N m 0 1 kgf m 0 8 lb...

Page 575: ...while slowly turning the rear wheel by your hand Is the voltage within standard value YES Faulty combination meter printed circuit board NO GO TO STEP 2 2 VS Sensor Power Input Voltage Inspection Turn...

Page 576: ...ine Short Circuit Inspection Check for continuity between the combination meter 28P connector of the wire side and ground Is there continuity YES Short circuit in Pink green wire NO Faulty VS sensor C...

Page 577: ...te hot spots that cause a bulb to break If you touch the bulb with your bare hands clean it with a cloth moistened with alcohol to prevent its early failure Install a new headlight bulb by aligning th...

Page 578: ...POSITION LIGHT BULB Turn the position light bulb socket counterclockwise and pull it out Remove the position light bulb from the bulb socket Installation is in the reverse order of removal REAR COMBIN...

Page 579: ...er cover page 3 10 Remove the screws trim clips and license light cover Remove the screws and lens cover Remove the bulb from the license light base Installation is in the reverse order of removal LUG...

Page 580: ...following Loose connector Blown METER fuse 5 A Faulty ignition switch page 23 26 Open or short circuit in Black orange wire BACK UP VOLTAGE INPUT LINE Measure the voltage between the combination mete...

Page 581: ...ue of the distance and fuel consumption after reset should be stored in EEPROM If the value is not stored _ _ _ under score EEPROM failure will be displayed when the ignition switch is turned ON and t...

Page 582: ...3 18 Disconnect the ECM 33P Black connector page 6 98 Disconnect the combination meter 28P Gray connector page 22 10 Check the continuity between the ECM 33P and combination meter connectors of the w...

Page 583: ...nish page 3 18 Connect the test harness 33P to the ECM 33P Black connector page 6 98 Disconnect the combination meter 28P Gray connector page 22 10 Check the continuity between the test harness and co...

Page 584: ...r voltage input lines and ground line page 22 10 Are the lines normal YES GO TO STEP 2 NO Faulty combination meter related circuit 2 VS Sensor Signal Input Line Inspection Turn the ignition switch OFF...

Page 585: ...printed cir cuit board Average fuel consumption indicator shows _ _ _ under score EEPROM failure with test harness 1 Reset The TRIP A Display the TRIP A by pressing the MODE but ton Push and hold the...

Page 586: ...ire 4 Injection Pulse Line Short Circuit Inspection Check the continuity between the combination meter 28P connector of the wire side and ground Is there continuity YES Short circuit in Brown white wi...

Page 587: ...rews and inner case printed circuit board from the lower case ASSEMBLY Assemble is in the reverse order of disassembly METER LENS SCREWS LOWER CASE SCREWS INNER CASE PRINTED CIRCUIT BOARD LOWER CASE S...

Page 588: ...does not move at running check as follows Remove the screen garnish page 3 18 Support the scooter on its center stand Jack up the scooter to rise the rear wheel off the ground Turn the ignition switc...

Page 589: ...here is no voltage check for open or short circuit in Yellow red or in Green black wire Turn the ignition switch OFF then disconnect the PCM 33P Black connector page 6 102 Check the continuity between...

Page 590: ...VS sensor 3P Black connector Support the scooter on its center stand Jack up the scooter to rise the rear wheel off the ground Turn the ignition switch ON engine stop switch Measure the voltage at th...

Page 591: ...ine starts check as follows Remove the screen garnish page 3 18 Connect the peak voltage adaptor to the combina tion meter 28P Gray connector terminal and ground with the connector connected Start the...

Page 592: ...etween the test harness and combination meter connector of the wire side There should be continuity If there is no continuity check for open circuit in Blue yellow wire SYSTEM INSPECTION NSS250A When...

Page 593: ...n meter and ECM 33P connectors of the wire side There should be continuity If there is no continuity check for open circuit in Blue yellow wire TACHOMETER SIGNAL LINE OPEN CIRCUIT INSPECTION WITH TEST...

Page 594: ...NOT MOVE Remove the luggage lower box page 3 16 Disconnect the ECT sensor 3P Gray connector Short the connector terminals of the wire side and ground with the jumper wire Immediately disconnect the ju...

Page 595: ...check the engine oil level page 4 10 Turn the ignition switch ON engine stop switch and check the oil pressure indicator If the indicator does not come on or the indicator stays on check the EOP switc...

Page 596: ...tely disconnect the jumper wire from the ground when the needle moves to F to prevent damage to gauge Turn the ignition switch ON engine stop switch and check the coolant temperature gauge The needle...

Page 597: ...S Check for continuity between the connector termi nals in each switch position Continuity should exist between the color code wires as shown in the charts LEFT HANDLEBAR SWITCH 12P CONNECTOR RIGHT HA...

Page 598: ...s as shown in the charts Turn Signal Switch 12P Blue connector Passing Switch 12P Blue connector Dimmer Switch 12P Blue connector Horn Switch 12P Blue connector PASSING SWITCH TURN SIGNAL SWITCH HORN...

Page 599: ...continuity between the connector termi nals in each switch position Continuity should exist between the color code wires as shown in the charts 2P CONNECTOR 12P CONNECTOR 8P CONNECTOR 3P CONNECTOR LEF...

Page 600: ...Blue connector Passing Switch 12P Blue connector Dimmer Switch 12P Blue connector Horn Switch 12P Blue connector Shift Switch 3P Black connector PASSING SWITCH TURN SIGNAL SWITCH HORN SWITCH SHIFT SW...

Page 601: ...ct the brake light switch connectors and check for continuity between the switch side termi nals There should be continuity with the left brake lever squeezed and there should be no continuity when th...

Page 602: ...AGE BOX LIGHT SWITCH NSS250A INSPECTION Remove the rear spoiler page 3 13 Disconnect the luggage box light switch connectors and check for continuity between the switch side terminals There should be...

Page 603: ...c tor Check the continuity between the wire terminals of the sidestand switch connector There should be continuity with the sidestand retracted There should be no continuity with the sidestand applied...

Page 604: ...ION Disconnect the horn connectors from the horn Connect a 12 V battery to the horn terminals The horn is normal if it sounds when the 12 V bat tery is connected across the horn terminals REMOVAL INST...

Page 605: ...the screen garnish page 3 18 Remove the turn signal relay and short the con nector terminal of the wire side and ground with the jumper wire Turn the ignition switch ON and engine stop switch and turn...

Page 606: ...Connect the 12 V battery to the following relay ter minals There should be continuity only when the 12 V bat tery is connected If there is no continuity when the 12 V battery is connected replace the...

Page 607: ...Y MODE 23 7 DIAGNOSTIC CODE INDICATION 23 8 TROUBLESHOOTING 23 10 TEST HARNESS CONNECTION 23 17 Honda Smart Card Key INDICATOR 23 18 HANDLE LOCK MODULE 23 19 LED HOLDER 23 28 RF UNIT 23 28 LF ANTENNA...

Page 608: ...Y FUSE 5 A CLOCK TRUNK ANSWER BACK FUSE 10 A ANSWER BACK RELAY CONSOLE BOX LOCK RELEASE ACTUATOR LED HOLDER HANDLE LOCK MODULE Honda Smart Card Key Honda Smart Card Key system ON OFF SWITCH Honda Smar...

Page 609: ...me such as by washing the clothes The handle lock module as well as the Honda smart card key must be replaced if all key have been lost Once the new Honda Smart Card Key is registered it is not usable...

Page 610: ...REGISTRATION CONNECTOR EM CONNECTOR SEAT LOCK RELEASE BUTTON CONSOLE BOX RELEASE BUTTON SEAT LOCK RELEASE ACTUATOR HANDLE LOCK MODULE CONSOLE BOX LOCK RELEASE ACTUATOR BANK ANGLE SENSOR ENGINE STOP RE...

Page 611: ...of the inspection adaptor from the battery positive terminal for more than two seconds then connect it again within two minutes The ignition switch light Blue LED turns on The Honda Smart Card Key Sys...

Page 612: ...four card key codes The four card keys can be registered 9 Turn the ignition switch OFF disconnect the inspection adaptor and connect the dummy connector to the registration connector The Honda Smart...

Page 613: ...fix When the ID number is 012345 Push the igni tion switch once without pressing the seat lock release button This operation indicates 0 Then Push the seat lock release button once and press ing the i...

Page 614: ...is abnor mal The blinking frequency is repeated for two minutes The ignition switch light Blue LED starts to blink when the system is normal The system is in the normal mode and the diagnostic code d...

Page 615: ...nt Faulty LF antenna or wire harness Follow the trouble shooting page 23 11 Code key sig nals cannot be received Faulty RF unit or wire harness Follow the trouble shooting page 23 12 Registration is o...

Page 616: ...ction Turn the ignition switch ON then measure the voltage at the combination meter connector Is there battery voltage YES Faulty combination meter NO Open or short circuit in Light green yellow wire...

Page 617: ...handle lock module 21P Black connector page 23 26 Check the continuity between the handle lock module 21P and LF antenna 2P connectors of the wire side Is there continuity YES GO TO STEP 2 NO Open ci...

Page 618: ...4 4 RF Unit Ground Line Inspection Check the continuity between the RF unit 5P connector of the wire side and ground Is there continuity YES GO TO STEP 5 NO Open circuit in Green black wire 5 RF Unit...

Page 619: ...ch light Blue LED starts blinking thirty seconds after the ignition switch is pushed Does the ignition switch blinks YES NSS250S Inspect the EM connector line page 23 25 NSS250A Inspect the EM connect...

Page 620: ...one and recheck Engine Does Not Start 1 Ignition Switch Inspection Check if the card key is recognized by the handle lock module and the ignition switch can be turned Can the ignition switch be turne...

Page 621: ...ck connector page 6 99 Handle lock module 21P Black connector page 23 26 Check the continuity between the handle lock module connector of the wire side and PCM ECM con nector of the wire side Is there...

Page 622: ...nspection Check if the Card Key is recognized by the handle lock module and the ignition switch can be turned Can the ignition switch be turned YES GO TO STEP 3 NO See The ignition switch cannot be tu...

Page 623: ...tween the main wire harness and handle lock module TEST HARNESS TERMINAL LAYOUT The handle lock module 21P Black connector ter minals are numbered as shown in the illustration The test harness 21P ter...

Page 624: ...ON Measure the voltage between the combination meter 28P Gray connector and ground There should be no voltage while the indicator is illuminated after the ignition switch is turned ON then the battery...

Page 625: ...s illumi nated after the ignition switch is turned ON If the battery voltage does not appear check for open circuit in Yellow white wire If the battery voltage appears faulty handle lock module INDICA...

Page 626: ...n the test harness and ground There should be battery voltage at all times without approx two seconds while the indicator is illumi nated after the ignition switch is turned ON If the battery voltage...

Page 627: ...the system is normal If there is no continuity check for open circuit in Green and or Green black wire HANDLE LOCK MODULE POWER CIRCUIT INSPECTION WITH TEST HARNESS Connect the test harness 21P betwee...

Page 628: ...ircuit in Yel low green wire HANDLE LOCK MODULE COMMUNICATION LINE INSPECTION NSS250S WITH TEST HARNESS Connect the test harnesses Handle lock module 21P Black connector and main harness page 23 17 EC...

Page 629: ...and main harness page 23 17 PCM 21P Black connector and main harness page 6 17 Check the continuity between the test harness 21P connectors There is continuity if the system is normal If there is no c...

Page 630: ...tor Release the registration 2P Red connector from the battery band Check the continuity between the test harness 21P and registration connector There is continuity if the system is normal If there is...

Page 631: ...m is normal If there is no continuity check for open circuit in Green black and or Black brown wire EM CONNECTOR LINE INSPECTION WITH TEST HARNESS Remove the battery cover page 19 6 Remove the dummy c...

Page 632: ...r wire Check each component for normal operation Each component does not operate normally check the following Open circuit in Red or Red black wire Blown MAIN B fuse 15 A Blown ECU IGN fuse 10A All co...

Page 633: ...L INSTALLATION Remove the handle lock module page 23 26 Remove the torx screws and ignition switch Installation is in the reverse order of removal Install the ignition switch to the handle lock mod ul...

Page 634: ...rmal Measure the voltage at the LED holder 3P connector of the wire side There should be battery voltage when the ignition switch is pushed RF UNIT INSPECTION Remove the fuse relay box page 3 17 Disco...

Page 635: ...ontinuity between the handle lock mod ule 21P and RF unit 5P connectors of the wire side There is continuity if the system is normal SIGNAL LINE INSPECTION WITH TEST HARNESS Connect the test harness 2...

Page 636: ...ANTENNA REMOVAL INSTALLATION Remove the rear meter panel page 3 22 Remove the trim clip and front actuator cover Turn the ignition switch OFF Disconnect the LF antenna 2P Natural connector Remove the...

Page 637: ...lue green wire INSPECTION WITH TEST HARNESS Connect the test harness 21P between the handle lock module 21P Black connectors and main har ness page 23 17 Check the continuity between the test harness...

Page 638: ...ermi nals in each switch position Continuity should exist between the color coded wires as follows CONSOLE BOX LOCK RELEASE ACTUATOR INSPECTION Remove the rear meter panel page 3 22 Connect the seat c...

Page 639: ...tor of the wire side and ground There should be continuity for a moment with each release button pushed REMOVAL INSTALLATION Remove the inner cover page 3 27 Disconnect the console box lock release ac...

Page 640: ...ied torque SEAT LOCK RELEASE ACTUATOR INSPECTION Remove the following Left body cover page 3 11 Seat lock cover page 3 13 Disconnect the seat lock release actuator 2P Gray connector Measure the voltag...

Page 641: ...sconnect the seat lock cable from the seat lock Remove the seat lock release actuator assembly Disconnect the seat lock release actuator 2P Gray connector and remove the seat lock release actuator ass...

Page 642: ...back relay connector terminals There should be continuity only when the 12 V bat tery is connected If there is no continuity when the 12 V battery is connected replace the answer back relay ANSWER BA...

Page 643: ...em 23 37 INSPECTION Check the continuity between the diode terminals When there is continuity a small resistance value will register If there is continuity in one direction the diode is normal C A B B...

Page 644: ...MEMO maxiscooter club ru...

Page 645: ...NDEX 24 13 DRIVETRAIN BLINK CODE DTC TROUBLESHOOTING 24 15 DRIVETRAIN BLINK CODE F blinks TROUBLESHOOTING 24 33 COMMUNICATION LINE WITH TEST PROBE 24 49 COMMUNICATION LINE WITH TEST HARNESS 24 50 MOVA...

Page 646: ...Honda S Matic System NSS250A 24 2 Honda S Matic System NSS250A COMPONENT LOCATION 3 5 N m 0 4 kgf m 2 6 lbf ft maxiscooter club ru...

Page 647: ...System diagnosis perform the PGM FI system diagnosis to make sure that engine related components are normal When checking the Honda S Matic System always follow the Self Diagnostic system page 24 8 Wh...

Page 648: ...er shaft 12 mm 07936 1660120 Driver 07749 0010000 Attachment 22 x 24 mm 07746 0010800 Imrie diagnostic tester model 625 or Peak voltage adaptor 07HGJ 0020100 with commercially available digital multim...

Page 649: ...maged movable drive pulley assembly Engine stalls or scooter creeps Broken clutch shoe spring Poor performance at acceleration Faulty ratio control motor Poor performance at high speed or lack of powe...

Page 650: ...c System NSS250A 24 6 SYSTEM LOCATION SHIFT SWITCH MODE SELECT SWITCH RATIO CONTROL MOTOR VS SENSOR DRIVEN PULLEY SENSOR MOVABLE DRIVE FACE POSITION SENSOR CKP SENSOR SENSOR UNIT TP SENSOR PCM maxisco...

Page 651: ...lack CONNECTOR C VS SENSOR EEPROM LCD COMBINATION METER SHIFT SWITCH MODE SELECT SWITCH MOVABLE DRIVE FACE POSITION SENSOR TP SENSOR CKP SENSOR DRIVEN PULLEY SENSOR RATIO MOTOR FUSE 30 A PCM 10P R Bl...

Page 652: ...age 6 14 INDICATOR BLINKING PATTERN The number of indicator blinks is the equivalent to main code of the DTC the sub code cannot be displayed by the indicator blinking The indicator has two types of b...

Page 653: ...f the MIL blinks refer to PGM FI Troubleshoot ing Information and troubleshooting the PGM FI system first Then recheck the Honda S Matic System after erasing the PGM FI DTC After performing diagnostic...

Page 654: ...trouble shoot the PGM FI system before readout erasing the Honda S Matic DTC Connect the HDS Pocket Tester to the DLC page 24 9 Erase the DTC s with the HDS while the engine is stopped To erase the DT...

Page 655: ...d incorrect peak volt age might be measured Use recommended digital multimeter or com mercially available digital multimeter with an impedance of 10 M DCV minimum Connect the peak voltage adaptor to t...

Page 656: ...LAYOUT The PCM connector terminals are numbered as shown in the illustration The test harness terminals are same layout as for the PCM connector terminals as shown 33P CONNECTOR 21P CONNECTOR TOOLS E...

Page 657: ...t accelerate Movable drive face not con trolled 24 15 24 33 6 1 6 Ratio control motor drive circuit Blown RATIO MOTOR fuse 30 A Loose or poor contact of the ratio control motor connector Open or short...

Page 658: ...face not con trolled 24 20 24 38 33 2 33 EEPROM malfunction Honda S Matic System initialization failure movable drive face position sensor or sensor shaft is not installed correctly EEPROM inside the...

Page 659: ...DTC 29 2 page 24 26 NO GO TO STEP 2 2 Ratio Control Motor Input Voltage Inspection Remove the left body cover page 3 11 Turn the ignition switch OFF Disconnect the PCM 5P Black connector Measure the...

Page 660: ...4 52 Check the continuity at the control motor 2P con nector terminals Is there continuity YES GO TO STEP 6 NO Faulty control motor 6 Ratio Control Motor Operation Inspection Apply battery voltage to...

Page 661: ...gear with your hand Does the movable drive face position shaft turn smoothly YES GO TO STEP 9 NO Ratio control motor and sensor shaft not synchronized with the program Inspect the following Reduction...

Page 662: ...GO TO STEP 12 NO Open or short circuit in Yellow black wire Open circuit in Green orange wire Replace the PCM with a known good one and recheck 12 Movable Drive Face Position Sensor Signal Line Conti...

Page 663: ...ion Install the following Movable drive face position sensor page 24 58 Ratio control motor page 24 53 Erase the DTC s from the PCM page 24 10 Perform the Honda S Matic System initial setting procedur...

Page 664: ...ove the left body cover page 3 11 Disconnect the PCM 5P Black connector Measure the voltage at the PCM 5P connector of the wire side Is there battery voltage YES GO TO STEP 3 NO Open or short circuit...

Page 665: ...uity between the ratio control motor 2P connector terminals Is there continuity YES GO TO STEP 6 NO Faulty ratio control motor 6 Ratio Control Motor Operation Inspection Apply battery voltage to the c...

Page 666: ...k connector page 6 102 Disconnect the VS sensor 3P Black connector page 22 20 Check the continuity between the PCM 33P and VS sensor 3P connectors of the wire side Is there continuity YES GO TO STEP 3...

Page 667: ...the engine and measure the peak voltage at the idle Is the voltage as specified YES Replace the PCM with a known good one and recheck NO GO TO STEP 2 2 Driven Pulley Sensor Peak Voltage Inspection at...

Page 668: ...cket tester Is about 0 V low voltage indicated YES GO TO STEP 2 NO Intermittent failure Loose or poor contact of the connec tor 2 Movable Drive Face Position Sensor Installation Inspection Turn the ig...

Page 669: ...STEP 6 NO Open or short circuit in Yellow black wire Open circuit in Green orange wire Replace the PCM with a known good one and recheck 6 Movable Drive Face Position Sensor Signal Line Continuity Ins...

Page 670: ...ace the PCM with a known good one and recheck NO Intermittent failure DTC 29 2 Movable drive face position sensor high voltage Movable drive face position sensor malfunction can be detected after star...

Page 671: ...r side Is the resistance within 0 6 0 k 20 C 68 F YES GO TO STEP 4 NO Faulty movable drive face position sen sor 4 Movable Drive Face Position Sensor Resistance Inspection 2 Measure the resistance at...

Page 672: ...ride the scooter then retrieve the problem code page 24 8 Is DTC 29 2 indicated YES Replace the PCM with a known good one and recheck NO Intermittent failure DTC 33 2 EEPROM 1 Failure Reproduction Era...

Page 673: ...tio Control Motor Input Voltage Line Inspection Remove the left body cover page 3 11 Turn the ignition switch OFF Disconnect the PCM 5P Black connector Measure the voltage at the PCM 5P connector of t...

Page 674: ...GO TO STEP 3 NO Open or short circuit in Yellow black wire Replace the PCM with a known good one and recheck 3 Shift Switch Signal Line Continuity Inspection Turn the ignition switch OFF Disconnect th...

Page 675: ...ector Check the continuity at the mode select switch 2P connector when the mode select switch pushed Is there continuity YES GO TO STEP 2 NO Faulty mode select switch 2 Mode Select Switch Input Voltag...

Page 676: ...4 Mode Select Switch Signal Line Short Circuit Inspection Check the continuity between the mode select switch 2P connector of the wire side and ground Is there continuity YES Short circuit in Blue ora...

Page 677: ...Disconnect the PCM 5P Black connector Measure the voltage at the PCM 5P connector of the wire side Is there battery voltage YES GO TO STEP 2 NO Open or short circuit in Red black wire Open circuit in...

Page 678: ...4 52 Check the continuity at the control motor 2P con nector terminals Is there continuity YES GO TO STEP 5 NO Faulty control motor 5 Ratio Control Motor Operation Inspection Apply battery voltage to...

Page 679: ...ace gear with your hand Does the movable drive face position sensor shaft turn smoothly YES GO TO STEP 8 NO Ratio control motor and sensor shaft not synchronized with the program Inspect the following...

Page 680: ...5 V YES GO TO STEP 11 NO Open or short circuit in Yellow black wire Open circuit in Green orange wire Replace the PCM with a known good one and recheck 11 Movable Drive Face Position Sensor Signal Lin...

Page 681: ...ll the following Movable drive face position sensor page 24 52 Ratio control motor page 24 53 Erase the DTC s from the PCM page 24 10 Perform the Honda S Matic System initial setting procedure page 24...

Page 682: ...pection Remove the left body cover page 3 11 Disconnect the PCM 5P Black connector Measure the voltage at the PCM 5P connector of the wire side Is there battery voltage YES GO TO STEP 3 NO Open or sho...

Page 683: ...y between the ratio control motor 2P connector terminals Is there continuity YES GO TO STEP 6 NO Faulty ratio control motor 6 Ratio Control Motor Operation Inspection Apply battery voltage to the cont...

Page 684: ...spection Connect the test harness 33P to the PCM 33P Black connector page 6 17 Disconnect the VS sensor 3P Black connector page 22 20 Check the continuity between the VS sensor 3P connector of the wir...

Page 685: ...test harness ter minals Place the scooter on its center stand Start the engine and measure the peak voltage at the idle Is the voltage as specified YES Replace the PCM with a known good one and rechec...

Page 686: ...age 24 61 1 Movable Drive Face Position Sensor Installation Inspection Remove the movable drive face position sensor page 24 51 Check if the slot of the movable drive face posi tion sensor and sensor...

Page 687: ...oltage within 4 75 5 25 V YES GO TO STEP 5 NO Open or short circuit in Yellow black wire Open circuit in Green orange wire Replace the PCM with a known good one and recheck 5 Movable Drive Face Positi...

Page 688: ...page 24 8 Does the meter display F blink 29 times YES Replace the PCM with a known good one and recheck NO Intermittent failure METER DISPLAY F 33 BLINKS EEPROM 1 Failure Reproduction Erase the DTC s...

Page 689: ...Ratio Control Motor Input Voltage Line Inspection Remove the left body cover page 3 11 Turn the ignition switch OFF Disconnect the PCM 5P Black connector Measure the voltage at the PCM 5P connector o...

Page 690: ...he wire side and ground Is the voltage within 4 75 5 25 V YES GO TO STEP 3 NO Open or short circuit in Yellow black wire Replace the PCM with a known good one and recheck 3 Shift Switch Signal Line Co...

Page 691: ...ch 2P Black connector Check the continuity at the mode select switch 2P connector when the mode select switch pushed Is there continuity YES GO TO STEP 2 NO Faulty mode select switch 2 Mode Select Swi...

Page 692: ...4 NO Open circuit in Blue orange wire 4 Mode Select Switch Signal Line Short Circuit Inspection Check the continuity between the mode select switch 2P connector of the wire side and ground Is there co...

Page 693: ...isconnect the PCM 33P Black connector page 6 102 Disconnect the combination meter 28P Gray connector page 22 10 Check the continuity between the combination meter 28P and PCM 33P connector of the wire...

Page 694: ...t the test harness 33P to the PCM 33P Black connector page 6 17 Disconnect the combination meter 28P Gray connector page 22 10 Check the continuity between the combination meter 28P connector and test...

Page 695: ...rt cir cuit in Yellow black wire and open circuit in Green orange wire Remove the movable drive face position sensor page 24 54 Measure the resistance at the position sensor 3P connector terminals Mak...

Page 696: ...holes Install the bolts and tighten them to the specified torque Connect the movable drive face position sensor 3P Black connector Perform the Honda S Matic System initial setting procedure page 24 6...

Page 697: ...TALLATION Be sure that the motor shaft is not contaminated Apply oil to a new O ring and install it to the ratio control motor groove Install the ratio control motor Install the stay and bolts Tighten...

Page 698: ...EAR MOVABLE DRIVE FACE POSITION SENSOR SHAFT REMOVAL When removing the movable drive face position sensor shaft reduction gear perform the Honda S Matic System initial setting procedure page 24 61 Rem...

Page 699: ...trol gear holder Remove the reduction gear B Remove the bolts and reduction gear A holder Remove the reduction gear A INSPECTION MOVABLE DRIVE FACE POSITION SENSOR SHAFT Check the sensor shaft gear fo...

Page 700: ...thly and quietly Also check that the outer race of the bearing fits tightly in the left crankcase Replace the bearings if the inner race do not turn smoothly quietly or if the outer race fit loosely i...

Page 701: ...0 mm 07936 GE00200 Remover weight 07741 0010201 GEAR B BEARING GEAR A BEARING REMOVER SHAFT REMOVER HEAD REMOVER WEIGHT TOOLS Driver 07749 0010000 Attachment 22 x 24 mm 07746 0010800 GEAR B BEARING GE...

Page 702: ...control gear holder and tighten the bolts Install the movable drive face position sensor page 24 58 MOVABLE DRIVE FACE POSITION SENSOR SHAFT INSTALLATION Make sure that the movable drive gear boss con...

Page 703: ...ure that the sensor shaft direction is within the tolerance as shown in the illustration If the sensor shaft direction can not be within the tolerance turn the shaft 180 and reinstall it Apply oil to...

Page 704: ...SOR REMOVAL INSTALLATION Remove the Driven pulley page 11 27 Disconnect the sub harness 10P Black connector Remove the bolts and driven pulley sensor stay Remove the grommet from the left crankcase Re...

Page 705: ...le drive pulley removal installation page 11 18 Before initializing the Honda S Matic System inspect the battery voltage page 19 7 make sure that the battery voltage is normal Before initializing the...

Page 706: ...ting the position of the drive pulley face and automati cally setting the position of the drive pulley face on 1st Be careful because the wheel rotates in varied speed 8 Check that the AM 5 is blinkin...

Page 707: ...25 1 25 25 WIRING DIAGRAMS NSS250S 25 3 NSS250A 25 4 maxiscooter club ru...

Page 708: ...26 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START 26 2 ENGINE LACKS POWER 26 3 POOR PERFORMANCE AT LOW AND IDLE SPEED 26 5 POOR PERFORMANCE AT HIGH SPEED 26 6 POOR HANDLING 26 7 maxiscooter...

Page 709: ...Starter Motor Inspection Check the starter motor turns Does the starter motor turn YES GO TO STEP 4 NO Faulty electric starter system page 21 4 4 PGM FI System Inspection Check the PGM FI system page...

Page 710: ...4 NO Clutch slipping Worn clutch shoes outer Weak driven face spring NSS250S Weight roller stuck 4 Engine Performance Inspection Accelerate lightly Does the engine speed increase YES GO TO STEP 5 NO...

Page 711: ...m page 6 19 10 lubrication Inspection Remove the cylinder head cover and inspect for sings of proper lubrication Is the valve train lubricated properly YES GO TO STEP 11 NO Clogged oil passage 11 Over...

Page 712: ...the PGM FI system page 6 14 Is the PGM FI system normal YES GO TO STEP 4 NO Faulty PGM FI system page 6 19 4 Intake Pipe Leaking Inspection Check for leaks at the intake manifold boot Does it leak YES...

Page 713: ...O TO STEP 4 NO Faulty PGM FI system page 6 19 4 Spark Plug Inspection Remove and inspect the spark plug Is the spark plug in good condition YES GO TO STEP 5 NO Plug not serviced frequently enough Inco...

Page 714: ...ight Damaged steering head bearings Either wheel is wobbles Excessive wheel bearing play Bent rim Excessively worn engine mounting bushing Bent frame The scooter pulls to one side Front and rear wheel...

Page 715: ...MEMO maxiscooter club ru...

Page 716: ...4 COOLING SYSTEM 4 13 COOLING SYSTEM SPECIFICATIONS 1 7 CRANKCASE ASSEMBLY 14 21 CRANKCASE BREATHER 4 7 CRANKCASE SEPARATION 14 5 CRANKCASE CRANKSHAFT BALANCER SPECIFICATIONS 1 9 CRANKPIN BEARING 14 1...

Page 717: ...AP COVER 3 35 N NUTS BOLTS FASTENERS 4 23 O O2 SENSOR 6 107 OIL PRESSURE INSPECTION 5 5 OIL PRESSURE RELIEF VALVE 5 7 OIL PUMP 5 9 OIL STRAINER 5 6 OPENER DAMPER 3 8 P PARKING BRAKE LEVER 16 15 PARKIN...

Page 718: ...20 2 LIGHTS METERS SWITCHES 22 2 SYSTEM TESTING COOLING SYSTEM 7 5 T TACHOMETER 22 21 TEST HARNESS CONNECTION 23 17 THERMOSTAT 7 10 THROTTLE BODY 6 82 THROTTLE OPERATION 4 5 TORQUE VALUES ENGINE FRAM...

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