Table Of Contents - Honda NPS50 RUCKUS 2003 Service Manual

Table of Contents

General Information2
Service Rules2
Model Identification2
Serial Numbers3
Labels4
General Specifications5
Lubrication System Specifications6
Fuel System Specifications6
Cooling System Specifications6
Cylinder Head/Valves Specifications7
Kickstarter/Drive Pulley/Driven Pulley/Clutch Specifications7
Final Reduction Specifications7
Crankshaft/Piston/Cylinder Specifications8
Rear Wheel/Brake/Suspension Specifications8
Battery/Charging System Specifications9
Ignition System Specifications9
Lights/Meters/Switches Specifications9
Standard Torque Values10
Engine & Frame Torque Values10
Lubrication & Seal Points13
Cable & Harness Routing15
Emission Control Systems34
Source Of Emissions34
Crankcase Emission Control System34
Exhaust Emission Control System35
Secondary Air Supply System35
Noise Emission Control System36
Oxidation Catalytic Converter36
Technical Features37
Pcv38
Frame/Body Panels/Exhaust System39
Body Panel Locations40
Service Information41
Troubleshooting41
Excessive Exhaust Noise41
Poor Performance41
Seat Removal42
Seat Installation42
Seat Rail43
Inner Cover43
Front Cover44
Floor Step45
Under Cover46
Rear Fender46
Muffler47
Muffler Protector47
Maintenance48
Maintenance Schedule50
Fuel Line51
Throttle Operation51
Air Cleaner52
Engine Breather53
Spark Plug53
Valve Clearance55
Engine Oil57
Oil Level Check57
Recommended Engine Oil57
Oil Change58
Engine Oil Strainer Screen59
Engine Idle Speed59
Radiator Coolant60
Cooling System60
Brake Shoes Wear62
Brake System63
Brake Lock Operation63
Headlight Aim64
Suspension64
Nuts, Bolts, Fasteners65
Wheels/Tires65
Steering Head Bearings66
Lubrication System67
Lubrication System Diagram68
Engine Oil Level Too Low69
Oil Contamination69
Oil Pump70
Fuel System75
Fuel System Component Locations76
Tools77
Engine Won't Start78
Engine Stall, Hard To Start, Rough Idling78
Lean Mixture78
Rich Mixture78
Air Cleaner Housing79
Carburetor Removal81
Carburetor Disassembly82
Starting Enrichment Valve83
Vacuum Chamber83
Float Chamber84
Carburetor Cleaning85
Carburetor Assembly86
Float Level Inspection87
Carburetor Installation89
Pilot Screw Adjustment92
Idle Drop Procedure92
Initial Opening92
Tentative Idle Speed92
High Altitude Adjustment94
High Altitude Pilot Screw Opening94
Input Voltage Inspection95
Resistance Inspection95
Operation Inspection96
Pair Control Valve Removal/Installation97
Pair Check Valve Inspection97
Specified Vacuum97
Pcv Control Solenoid Valve/Pcv Reed Valve98
Pcv Control Solenoid Valve101
Fuel Tank102
Pcv Reed Valve102
System Flow Pattern105
Engine Temperature Too High107
Engine Temperature Too Low107
Coolant Leak107
Coolant System Testing108
Coolant108
Coolant Specific Gravity Chart108
Radiator Cap/System Pressure Inspection109
Coolant Replacement109
Replacement/Air Bleeding110
Water Pump/Thermostat111
Thermostat Inspection113
Water Pump114
Radiator115
Radiator Reserve Tank117
Engine Removal/Installation119
Engine Removal122
Engine Installation125
Cylinder Head/Valves127
Compression Too Low131
Excessive Smoke131
Excessive Noise131
Rough Idle131
Cylinder Compression Test132
Cylinder Head Cover Removal132
Camshaft/Rocker Arms Removal133
Camshaft Inspection135
Cylinder Head Removal136
Cam Chain Tensioner Lifter136
Cylinder Head Disassembly137
Cylinder Head138
Valve Spring138
Valve/Valve Guide138
Valve Guide Replacement139
Valve Seat Inspection/Refacing140
Refacing141
Cylinder Head Assembly143
Cylinder Head Installation144
Camshaft/Rocker Arm Installation145
Rocker Arm Holder Assembly145
Cylinder Head Cover Installation148
Belt Case Cover154
Kickstarter154
Drive Pulley157
Drive Belt158
Weight Roller158
Movable Drive Face159
Clutch/Driven Pulley160
Clutch Outer162
Clutch Shoe Lining162
Driven Face Spring162
Driven Face/Movable Driven Face162
Driven Face Bearing Replacement163
Final Reduction167
Engine Does Start But Scooter Won't Move170
Abnormal Noise170
Oil Leak170
Final Reduction Oil171
Final Reduction Disassembly171
Transmission Disassembly171
Level Check171
Bearing Replacement174
Final Reduction Assembly175
Alternator/Starter179
Alternator/Starter Service Information181
Alternator/Starter Torque Values181
Alternator/Starter Tools181
Alternator/Starter Removal182
Crankshaft/Piston/Cylinder185
Crankcase Separation189
Crankshaft/Piston189
Crankshaft Removal189
Piston Removal190
Crankshaft Inspection190
Piston/Cylinder Inspection192
Piston Installation194
Crankshaft Installation194
Crankcase Assembly195
Front Wheel/Brake/Suspension/Steering197
Hard Steering202
Front Wheel Wobbles202
Front Wheel Hard To Turn202
Soft Suspension202
Front Wheel203
Wheel204
Wheel Bearing204
Front Brake207
Fork211
Handlebar215
Steering Stem219
Rear Wheel/Brake/Suspension224
Rear Wheel227
Rear Brake227
Rear Shock Absorber230
Battery/Charging System232
Battery Is Damaged Or Weak236
Battery Test236
Current Leakage Test236
Battery237
Voltage Inspection237
Charging System Inspection238
Battery Testing238
Battery Charging238
Alternator Charging Coil239
Engine Control Module240
Regulator/Rectifier Circuit Inspection240
Ignition Switch Circuit Inspection241
Battery Line241
Ground Line241
Charging Coil Line241
Main Relay242
Operating Inspection243
Main Relay Operation Voltage Inspection243
Main Relay Circuit Voltage Inspection243
Starter Relay Circuit Inspection243
Ignition System244
Ignition System Diagram245
Ignition System Inspection248
Ignition Coil Primary Peak Voltage248
Ignition Pulse Generator Peak Voltage249
Ignition Coil250
Ignition Timing250
Throttle Position Sensor251
Data Sheet253
Electric Starter254
Fuse Inspection257
Battery Inspection257
Starter Relay Operation Check257
Stator Coil Inspection257
Angle Sensor Circuit Inspection258
Starter Switch Circuit Inspection258
Starter Relay Battery Voltage Line Inspection258
Starter Relay259
Relay Circuit Inspection259
Battery Voltage Line259
Starter Circuit Inspection260
Lights/Meters/Switches262
Headlight Is Not Turned On266
Headlight Circuit266
Headlight Circuit Inspection266
Ground Line Inspection266
Turn Signal Light267
Bulb Replacement267
Turn Signal Relay Inspection267
Turn Signal Switch Inspection268
Brake/Tail Light269
Brake/Tail Light Does Not Operate269
Operation Of The Lights Inspection269
Brake Light Switch Inspection269
Brake Light Circuit Inspection270
Turn Signal Indicator271
High Beam Indicator271
Speedometer272
Fuel Reserve Indicator/Fuel Reserve Sensor273
Led Drive Unit Battery/Ground Line Inspection273
When The Fuel Reserve Indicator Does Not Light273
Fuel Reserve Sensor Line Inspection273
Fuel Indicator Line Inspection274
Resistor Line Inspection274
Resistor Inspection274
Fuel Reserve Sensor Removal275
Fuel Reserve Sensor Installation275
Coolant Temperature Indicator276
Ect Sensor276
Ect Sensor Circuit Inspection277
Ect Sensor Inspection278
Fuel Pump279
Fuel Pump Operation Check279
Fuel Pump Circuit Inspection279
Fuel Pump Operation Inspection280
Discharge Volume Inspection280
Fuel Pump Inspection280
Ignition Switch281
Handlebar Switches282
Left Handlebar Switch283
Right Handlebar Switch283
Brake Light Switch283
Horn284
Load Cut Relay284
Wiring Diagrams285
Engine Does Not Start Or Is Hard To Start289
Carburetor Inspection289
Spark Test289
Engine Start Condition289
Engine Lacks Power290
Drive Train Inspection290
Tire Pressure Inspection290
Drive Belt Inspection290
Engine Oil Inspection291
Ignition Timing Inspection291
Cylinder Compression Inspection291
Lubrication Inspection291
Poor Performance At Low And Idle Speed292
Spark Plug Inspection292
Carburetor Pilot Screw Inspection292
Poor Performance At High Speed293
Poor Handling294
Stearing Is Heavy294
Either Wheel Wobbles294
Index295