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LIGHTS/METERS/SWITCHES

THERMOSTATIC SWITCH

The cooling fan motor is actuated by the thermostatic switch
located in the bottom of the radiator.

If the fan motor does not start, disconnect the 2P: Black con-

nector from the switch.

Connect together Black/Blue and Green terminals of the 2P
connector with a suitable jumper wire.

Turn the ignition switch ON. The cooling fan motor should

start running. If it does not start, check for battery voltage

from the Black/Blue lead of the fan motor connector and
ground with ignition switch ON.

If there is no voltage, check for a blown fuse, loose terminals

or connectors, or an open circuit.

If there is voltage, inspect the thermostatic switch as follows:

Drain the coolant (page 5-4) and remove the thermostatic
switch.
Connect one lead of an ohmmeter to the connector of the

thermostatic switch and the other to the body.

Suspend the thermostatic switch in a pan of coolant (50 — 50
mixture) and check the temperatures at which the switch

opens and closes.

Make sure that there is no continuity at room temperature and

then gradually raise the coolant temperature. The switch
should show continuity (close) at 93°—97°C (199° —
207°F}.

NOTE

• Keep the temperature for 3 minutes to confirm continuity.

A sudden change of temperature will Cause an incorrect
temperature reading between the thermometer and switch.

• Do not let the switch or thermometer touch the pan as it will

give a false reading.

• Immerse the switch in coolant up to its threads.

Install the thermostatic switch.

TORQUE: 18 N*m (1.8 kg-m, 13ft-lb)

Fill the cooling system (page 5-4),

TEMPERATURE SENSOR

Disconnect the Green/Blue wire from the temperature sensor.

Check for continuity between the sensor body and ground.
There should be continuity.

If there is no continuity, check the thermostat housing for

looseness and recheck.

( 1 | THERMOSTATIC

SWITCH

(1) THERMOMETER

(2) THERMOSTATIC

SWITCH

(1 TEMPERATURE SENSOR

19-9

Summary of Contents for NX250 1989

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Page 58: ...1 it ibl 10 N m 11 0 kg m 7 1 0 NTTI 10 1 kfl rp 0 7 ft ib 13 N m 1 35 N w f3 5 ko m 25 fl Ui 14 N m fl 4 kg m 10 fi lbl 14 N rn 1 4 kg mH 0 ft ihl 3 N m 3 5 kg m 25 ft tbl 2 6 N m Or25 kq mr 1 S ft...

Page 59: ...ke assemblies Dse an OSHA approved vacuum cleaner or alternate methfd approved b OSHA designed to minimize ihe hazard by airborne aihestot fiheix SPECIFICATIONS ITEM Front dfsc thickness Front disc ru...

Page 60: ...ystem Pads glazed or excessively worn Brake drag Hydraulic System sticking Sticking pietonls Clogged hydraulic system Caliper slide pm slicking Disc or wheel misaligned Brake grab or pull to one Pads...

Page 61: ...FILLING BLEEDING Fill the master cylinder reservoir with DOT 4 brake fluid from a sealed container CAUTION Do not mix different types of fluid They are not compatible Connect a commercially available...

Page 62: ...cease to appear in the fluid coming out of the bleed valve Tighten the bleed valve TORQUE 6 N m 0 6 kg m 4 3 ft lb Fill the mster cylinder resevoir to the upper level mark with DOT 4 brake fluid from...

Page 63: ...t to the specified torque TORQUE 18 Nm 1 8 kg m 13 ft lb Tighten the pad pin plug to the specified torque TORQUE 2 5 N m 0 25 kg m 1 8 ft lb NOTE Operate the brake lever to seat the caliper pistons ag...

Page 64: ...r cylinder CAUTION When removing the brake hose cover the end of the hose to pre vent contamination Remove the brake lever by removing the pivot nut and bolt Remove the brake light switch by removing...

Page 65: ...ps with clean brake fluid then install the spring master piston and washer into the master cylinder 1 SPRING 2 PISTON CUPS 4 MASTER PISTON Install the snap ring and piston boot CAUTION Do not allow th...

Page 66: ...to clean brake assemblies Use an OSHA approved vacuum cleaner or alternate method approved by OSHA designed to minimize the hazard caused by airborne asbestos fibers DISASSEMBLY Drain the brake fluid...

Page 67: ...mm 1 0587 in neck the caliper clyinder bores for scoring or other damage Measure the caliper cylinder inside diameter SERVICE LIMIT 27 06 mm 1 065 in ASSEMBLY The dust and piston seals must be replace...

Page 68: ...stall the pads page 14 5 SILICONE 2 PAD SPRING 1 BOOT Install the caliper on the fork leg and over the brake disc so that the disc is positioned between the pads NOTE Use care not to damage the pads T...

Page 69: ...age 1 5 2 joint nuts connecting band bolt exhaust muffler bolts CAUTION Do not sit on the seat after removing the muffler Install the exhaust pipe muffler in the reverse order of removal 1 EXHAUST MUF...

Page 70: ...me then remove the side cover FAIRING INNER COVERS Remove the inner cover mounting bolts and covers Install the inner covers in the reverse order of removal SIDE FAIRING Remove the inner covers Remove...

Page 71: ...osen the carrier base 6 mm SH bolts more than five threads Remove the socket bolts and nuts Remove the rear carrier assembly by pulling upward white spreading both lower ends INSTALLATION Install the...

Page 72: ...FUSE 5t SUB FUSE 7 ALTERNATOR 6 REGULATOR RECTIFIER 6 TO CDI UNIT 4P CONNECTOR 5 ALTERNATOR ID IGNITION SWITCH RIB Bl 2 MAIN FUSE 20 A R W C X J O Y Y Y i i i R W 4 REGULATOR RECTIFIER 3 BATTERY 12 V...

Page 73: ...this motorcycle is a permanently sealed type Never remove the filler hole caps even when the battery is being charged Be sure to charge the battery with the amount of current and for the time indicat...

Page 74: ...t 20 C 68 F Output Charging start rpm STANDARD 12 V 6 AH 13 0 13 2 V at 25 C 12 3 V 0 6 amperes 10 Hr Three phase full wave rectify 13 5 15 5 V 5 000rpm 0 1 I Ofl 0 2 kw 5 000 rpm 1 000 100 rpm TOOLS...

Page 75: ...page 15 5 1 LOW VOLTAGE SAME AS BATTERY VOLTAGE i Measure the voltage between the R W and G wires and Bl and G with ignition switch ON of the regulator rectifier connector wire har ness side BATTERY V...

Page 76: ...ry terminals RED to positive SLACK to negative Turn the power switch ON After charging is complete retest the battery and recharge if necessary A WARMING The battery generates hydrogen gas which can b...

Page 77: ...lead to death Warm up the engine to normal operating temperature Sto the engine and connect the voltmeter as shown Connect the tachometer and restart the engine Allow the engine to idle and increase...

Page 78: ...BATTERY CHARGING SYSTEM REMOVAL INSTALLATION Disconnect the connector and remove the bolts and rectifier from the air cleaner case REGULATOR RECTIFIER 16 7...

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Page 94: ...Blue Lg Light Green Orange P Pink R Red W White Y Yellow To isolate an electrical failure check the continuity of the electrical path through the part A continuity check can usually be made without re...

Page 95: ...ground NO VOLTAGE LOW VOLTAGE Disconnect the temperature unit 2P connector and the G Bu wire from the meter and measure the voltage between the Bl 2P con nector and G Bu wire with ground NO VOLTAGE L...

Page 96: ...b with bare hands clean it with an alcohol moistened cloth before installing it in the case BULB REPLACEMENT Remove the dust cover Remove the retainer clip and headlight bulb 2 RETAINER CLIP CASE REMO...

Page 97: ...y Remove the mounting bolts and free the case from the fairing bracket then remove the speedometer 1 SPEEDOMETER CABLE Tachometer If the tachometer does not work properly turn the ignition switch ON a...

Page 98: ...terclockwise to remove Replace the bulb if necessary Install in the reverse order of removal NOTE Seat the rubber gasket properly Remove the license light cover mounting nuts and cover Remove the lens...

Page 99: ...ke light switch if necessary See page 3 14 for adjustment procedures CLUTCH SWITCH Disconnect the clutch switch connectors and check for conti nuity The switch should have continuity with the clutch l...

Page 100: ...Dimmer Switch Hi N Lo COLOR Hi Bu Turn Signal Switch R N L COLOR R Lb HL Bu W W 0 0 Gr Lo w L 0 11 LEFT HANDLEBAR SWITCH 1 RIGHT HANDLEBAR SWITCH Horn Switch FREE PUSH COLOR Bl Ho Lg HORN Disconnect...

Page 101: ...emove the igntion switch cover Drill the ignition switch stay special mounting bolts out with a sharp 4 mm 5 32 in drill bit Remove the ignition switch stay Remove the screws and ignition switch from...

Page 102: ...to the body Suspend the thermostatic switch in a pan of coolant 50 50 mixture and check the temperatures at which the switch opens and closes Make sure that there is no continuity at room temperature...

Page 103: ...11 TEMPERATURE SENSOR 2 THERMOMETER NOTE The coolant must be used as the heated liquid to check the function above 100 C 212 Fh You will get false readings if either the sensor or thermometer touches...

Page 104: ...STARTER ENQNE STOP THERMO SWITCH R BRAKE UGHT SWITCH SWITCH CONTNXTY IGMTON SWiTCM ON Off LOCK COLOR FAN Bo O ENO NE STOP SWITCH OFF COLOR 1 BAT6 B R STARTER SWITCH PUSH COLOR Y R HLI HL2 N L COLOR W...

Page 105: ...N ENGINE DOES NOT START Probable Cause Clogged fuel tube or fuel strainer Clogged float valve Clogged fuel tank cap breather tube Faulty spark plug Fouled spark plug Faulty CDI unit Broken or shorted...

Page 106: ...NGINE SPEED DOES NOT INCREASE SUFFICIENTLY INCORRECT INCORRECT TOO LOW CLOGGED FOULED OR DISCOLORED Probable Cause Brake dragging Worn or damaged wheel bearing Wheel bearing needs lubrication Drive ch...

Page 107: ...ixture too lean Use of improper grade of fuel Excessive carbon build up in com bustion chamber Ignition timing too advanced Faulty CDI unit POOR PERFORMANCE AT LOW AND IDLE SPEEDS 1 Check ignition tim...

Page 108: ...gged jet s Clean them NOT CLOGGED 4 Check valve timing INCORRECT CORRECT 5 Check valve spring tension WEAK NOT WEAKENED 6 Check spark arrester for clogging Probable Cause Improper valve clearance Faul...

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