Honda NSS250A Reflex 2001-2007 Скачать руководство пользователя страница 289 | Manualshive

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ENGINE REMOVAL/INSTALLATION

8-9

ENGINE INSTALLATION

• Before installing the engine, route the wires, hoses, and cables properly (page 1-21).

Coat new O-rings with molybdenum disulfide paste
and install them to the engine mounting bushing
grooves.
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 (6.0 kgf·m, 44 lbf·ft)

20 N·m (2.0 kgf·m, 15 lbf·ft)

59 N·m (6.0 kgf·m, 44 lbf·ft)

ENGINE HANGER BRACKET

O-RINGS

BUSHINGS

O-RINGS

59 N·m (6.0 kgf·m,
44 lbf·ft)

TENSION ROD

COLLAR

BUSHINGS

O-RINGS

NUTS/BOLTS

ENGINE HANGER BRACKET

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Содержание NSS250A Reflex 2001-2007

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 68: ...MEMO maxiscooter club ru...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 114: ...MEMO maxiscooter club ru...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 140: ...MEMO maxiscooter club ru...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 154: ...MEMO maxiscooter club ru...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 280: ...MEMO maxiscooter club ru...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 294: ...MEMO maxiscooter club ru...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 366: ...MEMO maxiscooter club ru...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 418: ...MEMO maxiscooter club ru...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 450: ...MEMO maxiscooter club ru...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 542: ...MEMO maxiscooter club ru...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 554: ...MEMO maxiscooter club ru...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 644: ...MEMO maxiscooter club ru...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 715: ...MEMO maxiscooter club ru...

Страница 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...

Страница 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...

Страница 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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