Honda NSS250S Manual
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Honda NSS250S Manual

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Table of Contents

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Download this manual See also: Service Manual, Owner's Manual
NSS250S/A TYPE CODE
• Throughout this manual, the following abbreviations are used to identify individual model.
CODE
AREA TYPE
EUROPEAN DIRECT SALES
(Austria, Belgium, Bulgaria, Croatia, Czech, Denmark, Finland, Germany,
ED
Greece, Holland, Hungary, Iceland, Israel, Italy, Latvia, Luxembourg,
Macedonia, Norway, Poland, Portugal, Romania, Russia, Slovakia, Slovenia,
Spain, Sweden, Switzerland, Ukraine)
F
France
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  • Page 1 NSS250S/A TYPE CODE • Throughout this manual, the following abbreviations are used to identify individual model. CODE AREA TYPE EUROPEAN DIRECT SALES (Austria, Belgium, Bulgaria, Croatia, Czech, Denmark, Finland, Germany, Greece, Holland, Hungary, Iceland, Israel, Italy, Latvia, Luxembourg, Macedonia, Norway, Poland, Portugal, Romania, Russia, Slovakia, Slovenia,...
  • Page 2 Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle.
  • Page 3 THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAIL- ABLE AT THE TIME OF APPROVAL FOR Honda Smart Card Key System PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE CHANGES AT ANY Honda S Matic System (NSS250A) TIME WITHOUT NOTICE WITHOUT...
  • Page 4 Example: Molykote ® G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease. Apply a locking agent. Use a middle strength locking agent unless otherwise specified.

  • Page 5: Table Of Contents

    SPECIFICATIONS ····································· 1-11 CYLINDER HEAD/VALVES SPECIFICATIONS········································ 1-8 LIGHTS/METERS/SWITCHES SPECIFICATIONS ····································· 1-11 CYLINDER/PISTON SPECIFICATIONS ······ 1-8 Honda S Matic System DRIVE PULLEY/DRIVEN PULLEY/CLUTCH SPECIFICATIONS (NSS250A) ·················· 1-12 SPECIFICATIONS········································ 1-9 STANDARD TORQUE VALUES ··············· 1-13 FINAL REDUCTION SPECIFICATIONS ······ 1-9 ENGINE & FRAME TORQUE VALUES ···· 1-13 ALTERNATOR/STARTER CLUTCH SPECIFICATIONS········································...

  • Page 6: Service Rules

    SERVICE RULES GENERAL INFORMATION 1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications may cause damage to the scooter. 2. Use the special tools designed for this product to avoid damage and incorrect assembly.

  • Page 7: Model Identification

    maxiscooter-club.ru GENERAL INFORMATION MODEL IDENTIFICATION The frame serial number is stamped on the right side of the frame. FRAME SERIAL NUMBER The engine serial number is stamped on the left side of the crankcase. NSS250A shown: ENGINE SERIAL NUMBER...
  • Page 8 maxiscooter-club.ru GENERAL INFORMATION The throttle body identification number is stamped on the lower side THROTTLE BODY IDENTIFICATION NUMBER of the throttle body. LABEL The color label is attached as shown. When ordering color-coded parts, NSS250A shown: always specify the designated color code. COLOR LABEL...

  • Page 9: General Specifications

    GENERAL INFORMATION GENERAL SPECIFICATIONS NSS250S ITEM SPECIFICATION DIMENSIONS Overall length 2,185 mm (86.0 in) Overall width 750 mm (29.5 in) Overall height 1,180 mm (46.5 in) Wheelbase 1,545 mm (60.8 in) Seat height 710 mm (28.0 in) Ground clearance 135 mm (5.3 in)
  • Page 10 maxiscooter-club.ru GENERAL INFORMATION NSS250A ITEM SPECIFICATION DIMENSIONS Overall length 2,185 mm (86.0 in) Overall width 750 mm (29.5 in) Overall height 1,180 mm (46.5 in) Wheelbase 1,545 mm (60.8 in) Seat height 710 mm (28.0 in) Ground clearance 135 mm (5.3 in) Curb weight 204 kg (450 lbs) Maximum weight capacity...

  • Page 11: Specifications

    1.4 liter (1.5 US qt, 1.2 Imp qt) – After disassembly 1.7 liter (1.8 US qt, 1.5 Imp qt) – Recommended engine oil Honda "4-stroke motorcycle oil" or an equivalent Oil recommendation: API classification: SG or higher (except oils labeled as energy con- –...

  • Page 12: Cylinder Head/Valves

    maxiscooter-club.ru GENERAL INFORMATION CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder compression 1,569 kPa (16.0 kgf/cm , 228 psi) at – 350 min (rpm) Cylinder head warpage – 0.05 (0.002) Camshaft Cam lobe height 39.285 – 39.525 (1.5467 – 1.5561) 39.235 (1.5447) 36.944 –...

  • Page 13: Specifications

    After disassembly 0.30 liter (0.32 US qt, 0.26 Imp qt) Recommended final reduction oil Honda "4-stroke motorcycle oil" or an equivalent Oil recommendation: API classification: SG or higher (except oils labeled as energy conserving on the circular...
  • Page 14 Fork Spring free length 325.3 (12.8) 315.5 (12.4) Tube runout – 0.2 (0.01) Honda Ultra Cushion Oil 10 W or Recommended fork fluid – equivalent Fluid level 90 (3.5) – 204 ± 2.5 cm (6.9 ± 0.08 US oz, 7.2 ±...

  • Page 15: Specifications

    LED x 6 Turn signal indicator LED x 2 High beam indicator Parking brake indicator Oil pressure indicator Honda smart card key indicator ABS warning indicator (NSS250A) S mode indicator (NSS250A) D mode indicator (NSS250A) A/M mode indicator (NSS250A) Fuse...
  • Page 16 GENERAL INFORMATION Honda S Matic System SPECIFICATIONS (NSS250A) Unit: mm (in) ITEM STANDARD SERVICE LIMIT Movable drive face position sensor resistance 0 – 6.0 kΩ – Driven pulley sensor peak voltage 0.7 V minimum – 1-12...
  • Page 17 maxiscooter-club.ru GENERAL INFORMATION STANDARD TORQUE VALUES TORQUE TORQUE FASTENER TYPE FASTENER TYPE N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft) 5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1) 6 mm bolt and nut 6 mm screw 9.0 (0.9, 6.6) (Include SH flange bolt) 10 (1.0, 7)
  • Page 18 maxiscooter-club.ru GENERAL INFORMATION LUBRICATION SYSTEM THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Oil pump cover screw 2 (0.2, 1.5) Oil pump driven sprocket bolt 12 (1.2, 9) Apply oil to the threads, Left-hand threads. EOP switch PT1/8 12 (1.2, 9) Apply sealant to the threads (TB1207B or equivalent).

  • Page 19: Front Wheel/Suspension/Steering

    maxiscooter-club.ru GENERAL INFORMATION DRIVE PULLEY/DRIVEN PULLEY/CLUTCH THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Clutch outer nut 74 (7.5, 55) Screw holder socket bolt (NSS250A) 10 (1.0, 7) Stopper arm socket bolt (NSS250A) 10 (1.0, 7) Stopper plate socket bolt (NSS250A) 10 (1.0, 7) Drive face bolt...

  • Page 20: Electric Starter

    26 (2.7, 19) Rearview mirror lock nut 26 (2.7, 19) Left-hand threads Pad pin 17 (1.7, 13) Brake pipe joint nut (NSS250S) 14 (1.4, 10) Apply brake fluid to the threads. Brake pipe joint nut (NSS250A) 14 (1.4, 10) Apply brake fluid to the threads.

  • Page 21: Lights/Meters/Switches

    Front turn signal light switch screw 1.0 (0.1, 0.7) Headlight screw 1.1 (0.1, 0.8) License light nut 1.5 (0.2, 1.1) U-nut Rear combination light screw 1.0 (0.1, 0.7) Honda Smart Card Key System THREAD TORQUE ITEM Q'TY REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Actuator screw 0.7 (0.1, 0.5)

  • Page 22: Lubrication & Seal Points

    Movable drive face position sensor shaft journal Fill up 0.10 – 0.20 g (0.004 – (NSS250A) 0.007 oz) Movable drive pulley dust seal lips (NSS250S) Movable driven pulley face oil seal lips Each oil seal lips and other surface Molybdenum oil solu-...
  • Page 23 maxiscooter-club.ru GENERAL INFORMATION MATERIAL LOCATION REMARKS Molybdenum disulfide Engine mounting bushing groove Fill up 0.50 – 0.70 g (0.018 – paste (containing more 0.025 oz) than 40% molybdenum Screw gear threads (NSS250A) Fill up 4.0 – 5.0 g (0.14 – 0.18 disulfide, NLGI #2 or equivalent) Drive shaft collar groove...
  • Page 24 DOT 4 brake fluid Caliper piston seal whole surface Caliper piston outer surface Piston cup whole surface Master cylinder inner surface, master piston outer sur- face Honda Bond A or equiv- Air cleaner resonator contacting area alent Handlebar grip rubber inside 1-20...

  • Page 25: Cable & Harness Routing

    GENERAL INFORMATION CABLE & HARNESS ROUTING NSS250S LEFT TURN SIGNAL/POSITION/HEADLIGHT 4P (Gray) CONNECTOR RIGHT TURN SIGNAL/POSITION/HEADLIGHT 4P (Blue) CONNECTOR LEFT POSITION LIGHT WIRE RIGHT POSITION LIGHT WIRE RIGHT HEADLIGHT 3P (Natural) CONNECTOR LEFT HEADLIGHT 3P (Black) CONNECTOR LEFT TURN SIGNAL LIGHT 3P (Black) CONNECTOR...
  • Page 26 maxiscooter-club.ru GENERAL INFORMATION RIGHT BRAKE HOSE LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE LEFT BRAKE HOSE THROTTLE CABLES RIGHT HANDLEBAR BRAKE LIGHT SWITCH WIRE SWITCH WIRE INHIBITOR SWITCH WIRE BRAKE LIGHT SWITCH WIRE TURN SIGNAL RELAY TURN SIGNAL RELAY CONNECTOR BANK ANGLE SENSOR 3P (Black) CONNECTOR INSIDE BOOT CONNECTORS: –...
  • Page 27 maxiscooter-club.ru GENERAL INFORMATION CONSOLE BOX LOCK RELEASE LEFT BRAKE HOSE ACTUATOR 2P (Gray) CONNECTOR RIGHT BRAKE HOSE JUNCTION 12P (Black) CONNECTOR ANSWER BACK DIODE BANK ANGLE SENSOR WIRE INSIDE BOOT CONNECTORS: – RIGHT TURN SIGNAL/POSITION/HEADLIGHT 4P (Blue) CONNECTOR – LEFT TURN SIGNAL/POSITION/HEADLIGHT 4P (Gray) CONNECTOR 1-23...
  • Page 28 maxiscooter-club.ru GENERAL INFORMATION COMBINATION METER 28P (Gray) CONNECTOR SEAT/CONSOLE BOX LOCK RELEASE BUTTON SWITCH 4P (Black) CONNECTOR RIGHT BRAKE HOSE LEFT BRAKE HOSE THROTTLE CABLES FRONT BRAKE HOSE (LEFT BRAKE LINE) FRONT BRAKE HOSE WATER HOSES 1-24...
  • Page 29 maxiscooter-club.ru GENERAL INFORMATION SEAT/CONSOLE BOX LOCK RELEASE BUTTON WIRE LEFT TURN SIGNAL/HEADLIGHT WIRE CONSOLE BOX LOCK RELEASE ACTUATOR 2P (Gray) CONNECTOR LF ANTENNA WIRE CONSOLE BOX LOCK CABLE MECHANICAL KEY CABLE FUEL LID LOCK CABLE SEAT LOCK CABLE LEFT TURN SIGNAL WIRE BREATHER AIR HOSE FUEL TANK OVERFLOW HOSE...
  • Page 30 maxiscooter-club.ru GENERAL INFORMATION LF ANTENNA 2P (Natural) CONNECTOR SEAT/CONSOLE BOX LOCK RELEASE BUTTON WIRE JUNCTION 20P (Blue) CONNECTOR LF ANTENNA WIRE JUNCTION 20P (Black) CONNECTOR HANDLE LOCK MODULE FRONT BRAKE PIPE 21P (Gray) CONNECTOR (LEFT BRAKE LINE) LED HOLDER 3P (Black) IGNITION SWITCH WIRE CONNECTOR HORN WIRE...
  • Page 31 maxiscooter-club.ru GENERAL INFORMATION LEFT BRAKE PIPE REAR BRAKE HOSE WHITE PAINT MARK FRONT BRAKE PIPE (LEFT BRAKE LINE) HANDLE LOCK MODULE 21P (Gray) CONNECTOR LED HOLDER 3P (Black) CONNECTOR TURN SIGNAL RELAY WIRE RIGHT BRAKE HOSE LEFT BRAKE HOSE LEFT BRAKE PIPE RIGHT BRAKE PIPE 1-27...
  • Page 32 maxiscooter-club.ru GENERAL INFORMATION CONSOLE BOX LOCK CABLE ANSWER BACK DIODE SEAT/CONSOLE BOX LOCK TURN SIGNAL RELAY RELEASE BUTTON WIRE LF ANTENNA WIRE FUEL LID LOCK CABLE SEAT LOCK CABLE CONSOLE BOX LOCK CABLE FUEL LID LOCK CABLE SEAT LOCK CABLE 1-28...
  • Page 33 maxiscooter-club.ru GENERAL INFORMATION BREATHER HOSE A BREATHER HOSE A SEPARATOR BREATHER HOSE BREATHER HOSE B WHITE PAINT MARK WHITE PAINT MARK BREATHER HOSE B BREATHER AIR HOSE BREATHER HOSE C BREATHER HOSE C 1-29...
  • Page 34 maxiscooter-club.ru GENERAL INFORMATION REGULATOR/RECTIFIER 2P (Black) CONNECTOR SEAT LOCK CABLE SEAT LOCK RELEASE ACTUATOR WIRE SEAT LOCK CABLE REAR BRAKE/TURN SIGNAL/ CKP SENSOR 2P (Red) LICENSE LIGHT WIRE CONNECTOR REAR BRAKE PIPE PARKING BRAKE CABLE REAR BRAKE HOSES MAIN HARNESS SPARK PLUG WIRE ALTERNATOR 3P (Black) CONNECTOR WATER HOSE...
  • Page 35 maxiscooter-club.ru GENERAL INFORMATION ALTERNATOR WIRE SPARK PLUG WIRE IGNITION COIL MAIN HARNESS IGNITION COIL CONNECTORS 1-31...
  • Page 36 maxiscooter-club.ru GENERAL INFORMATION JUNCTION 12P (Black) CONNECTOR SEAT LOCK CABLE MAIN HARNESS THROTTLE CABLES SEAT LOCK CABLE ECM 33P (Black) CONNECTOR WATER HOSES FUEL FEED HOSE THROTTLE CABLES SIDESTAND SWITCH 2P (Gray) CONNECTOR FUEL FEED HOSE GROUND TERMINAL WATER HOSES 1-32...
  • Page 37 maxiscooter-club.ru GENERAL INFORMATION PAIR CONTROL SOLENOID VALVE 2P (Black) CONNECTOR SECONDARY AIR SUPPLY HOSES VS SENSOR WIRE RIGHT CRANKCASE COVER BREATHER HOSE IACV 4P (Black) CONNECTOR SENSOR 1P (Black) CONNECTOR FUEL FEED HOSE SENSOR WIRE SECONDARY AIR SUPPLY HOSE WATER HOSES SPARK PLUG WIRE EOP SWITCH WIRE 1-33...
  • Page 38 maxiscooter-club.ru GENERAL INFORMATION THROTTLE CABLES SENSOR UNIT 5P (Black) CONNECTOR ECT SENSOR 3P PAIR CONTROL (Gray) CONNECTOR SOLENOID VALVE 2P (Black) CONNECTOR INJECTOR 2P (Gray) CONNECTOR ALTERNATOR WIRE WATER HOSES 1-34...
  • Page 39 maxiscooter-club.ru GENERAL INFORMATION SENSOR 1P (Black) CONNECTOR RIGHT CRANKCASE BREATHER HOSE VS SENSOR/EOP SWITCH 4P (Black) CONNECTOR VS SENSOR WIRE 1-35...
  • Page 40 maxiscooter-club.ru GENERAL INFORMATION SPARK PLUG WIRE FUEL PUMP UNIT 5P (Natural) CONNECTOR FUEL FEED HOSE MAIN HARNESS GROUND CABLES SEAT LOCK RELEASE ACTUATOR 2P (Gray) CONNECTOR 1-36...
  • Page 41 maxiscooter-club.ru GENERAL INFORMATION VS SENSOR/EOP SWITCH 4P (Black) CONNECTOR THROTTLE CABLES WIRE HARNESS STARTER MOTOR CABLE EOP SWITCH WIRE VS SENSOR WIRE GROUND CABLES 1-37...
  • Page 42 maxiscooter-club.ru GENERAL INFORMATION FINAL DRIVE CASE BREATHER HOSE 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 DLC 4P (Red) JUNCTION 20P (Natural) CONNECTOR JUNCTION 14P (Orange) CONNECTOR 1-38...
  • Page 43 maxiscooter-club.ru GENERAL INFORMATION RF UNIT WIRE BATTERY (–) CABLE BATTERY (+) CABLE BATTERY (–) CABLES MAIN HARNESS BATTERY (–) CABLE LICENSE LIGHT 3P (Gray) CONNECTOR TURN SIGNAL/TAIL/BRAKE LIGHT 5P (Gray) CONNECTOR LICENSE LIGHT MAIN HARNESS 1-39...
  • Page 44 maxiscooter-club.ru GENERAL INFORMATION RIGHT BRAKE/TAIL LIGHT 3P (Natural) CONNECTOR LEFT BRAKE/TAIL LIGHT 3P (Natural) CONNECTOR RIGHT REAR TURN SIGNAL LIGHT WIRE LEFT REAR TURN SIGNAL LIGHT WIRE LICENSE LIGHT 3P (Gray) CONNECTOR TURN SIGNAL/TAIL/BRAKE LIGHT 5P (Gray) CONNECTOR 1-40...
  • Page 45 maxiscooter-club.ru GENERAL INFORMATION NSS250A LEFT TURN SIGNAL/POSITION/HEADLIGHT 4P (Gray) CONNECTOR RIGHT TURN SIGNAL/POSITION/HEADLIGHT 4P (Blue) CONNECTOR LEFT POSITION LIGHT WIRE RIGHT POSITION LIGHT WIRE RIGHT HEADLIGHT 3P (Natural) CONNECTOR LEFT HEADLIGHT 3P (Black) CONNECTOR LEFT TURN SIGNAL LIGHT 3P (Black) CONNECTOR RIGHT TURN SIGNAL LIGHT 3P (Natural) CONNECTOR 1-41...
  • Page 46 maxiscooter-club.ru GENERAL INFORMATION RIGHT BRAKE HOSE LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE LEFT BRAKE HOSE THROTTLE CABLES RIGHT HANDLEBAR BRAKE LIGHT SWITCH WIRE SWITCH WIRE INHIBITOR SWITCH WIRE BRAKE SWITCH WIRE TURN SIGNAL RELAY TURN SIGNAL RELAY CONNECTOR BANK ANGLE SENSOR 3P (Black) CONNECTOR INSIDE BOOT CONNECTORS: –...
  • Page 47 maxiscooter-club.ru GENERAL INFORMATION CONSOLE BOX LOCK RELEASE LEFT BRAKE HOSE ACTUATOR 2P (Gray) CONNECTOR RIGHT BRAKE HOSE ANSWER BACK DIODE JUNCTION 12P (Black) CONNECTOR ABS CONTROL UNIT WIRE BANK ANGLE SENSOR WIRE INSIDE BOOT CONNECTORS: – RIGHT TURN SIGNAL/POSITION/HEADLIGHT 4P (Blue) CONNECTOR –...
  • Page 48 maxiscooter-club.ru GENERAL INFORMATION COMBINATION METER 28P (Gray) CONNECTOR SEAT/CONSOLE BOX LOCK RELEASE BUTTON 4P (Black) CONNECTOR RIGHT BRAKE HOSE LEFT BRAKE HOSE THROTTLE CABLES FRONT BRAKE HOSE (LEFT BRAKE LINE) FRONT BRAKE HOSE WATER HOSES 1-44...
  • Page 49 maxiscooter-club.ru GENERAL INFORMATION SEAT/CONSOLE BOX LOCK RELEASE BUTTON WIRE LEFT TURN SIGNAL/HEADLIGHT WIRE CONSOLE BOX LOCK RELEASE ACTUATOR 2P (Gray) CONNECTOR LF ANTENNA WIRE CONSOLE BOX LOCK CABLE MECHANICAL KEY CABLE FUEL LID LOCK CABLE SEAT LOCK CABLE LEFT TURN SIGNAL WIRE BREATHER AIR HOSE FUEL TANK OVERFLOW HOSE...
  • Page 50 maxiscooter-club.ru GENERAL INFORMATION LF ANTENNA 2P (Natural) CONNECTOR SEAT/CONSOLE BOX LOCK RELEASE BUTTON WIRE JUNCTION 20P (Blue) CONNECTOR LF ANTENNA WIRE JUNCTION 20P (Black) CONNECTOR FRONT BRAKE PIPE HANDLE LOCK MODULE (LEFT BRAKE LINE) 21P (Gray) CONNECTOR IGNITION LED HOLDER 3P (Black) SWITCH WIRE CONNECTOR PARKING BRAKE...
  • Page 51 maxiscooter-club.ru GENERAL INFORMATION REAR BRAKE PIPE FRONT BRAKE PIPE (LEFT BRAKE LINE) HANDLE LOCK MODULE 21P (Gray) CONNECTOR LED HOLDER 3P (Black) CONNECTOR FRONT WHEEL SPEED SENSOR 2P (Blue) CONNECTOR TURN SIGNAL RELAY WIRE RIGHT BRAKE PIPE RIGHT BRAKE HOSE ABS MODULATOR 25P CONNECTOR LEFT BRAKE HOSE LEFT BRAKE PIPE...
  • Page 52 maxiscooter-club.ru GENERAL INFORMATION CONSOLE BOX LOCK CABLE ANSWER BACK DIODE SEAT/CONSOLE BOX LOCK TURN SIGNAL RELAY RELEASE BUTTON WIRE LF ANTENNA WIRE FUEL LID LOCK CABLE SEAT LOCK CABLE CONSOLE BOX LOCK CABLE FUEL LID LOCK CABLE SEAT LOCK CABLE 1-48...
  • Page 53 maxiscooter-club.ru GENERAL INFORMATION BREATHER HOSE A BREATHER HOSE A SEPARATOR BREATHER HOSE BREATHER HOSE B WHITE PAINT MARK WHITE PAINT MARK BREATHER HOSE B BREATHER AIR HOSE BREATHER HOSE C BREATHER HOSE C 1-49...
  • Page 54 maxiscooter-club.ru GENERAL INFORMATION REGULATOR/RECTIFIER 2P (Black) CONNECTOR LUGGAGE BOX SWITCH 2P CONNECTOR LUGGAGE BOX LIGHT SEAT LOCK CABLE SWITCH WIRE SEAT LOCK RELEASE ACTUATOR WIRE SEAT LOCK CABLE CKP SENSOR 2P (Red) REAR BRAKE/TURN SIGNAL/ CONNECTOR LICENSE LIGHT WIRE REAR BRAKE PIPE PARKING BRAKE CABLE REAR BRAKE HOSES MAIN HARNESS...
  • Page 55 maxiscooter-club.ru GENERAL INFORMATION ALTERNATOR WIRE SPARK PLUG WIRE IGNITION COIL MAIN HARNESS IGNITION COIL CONNECTORS 1-51...
  • Page 56 maxiscooter-club.ru GENERAL INFORMATION LUGGAGE BOX LIGHT WIRE JUNCTION 24P (Black) CONNECTOR SEAT LOCK CABLE MAIN HARNESS PCM 21P (Black) CONNECTOR THROTTLE CABLES SEAT LOCK CABLE PCM 5P (Black) CONNECTOR PCM 33P (Black) CONNECTOR WATER HOSES FUEL FEED HOSE THROTTLE CABLES SIDESTAND SWITCH 2P (Gray) CONNECTOR FUEL FEED HOSE GROUND TERMINAL...
  • Page 57 maxiscooter-club.ru GENERAL INFORMATION PAIR CONTROL SOLENOID VALVE 2P (Black) CONNECTOR SECONDARY AIR SUPPLY HOSES VS SENSOR/DRIVEN PULLEY SENSOR WIRE RIGHT CRANKCASE COVER BREATHER HOSE REAR WHEEL SPEED SENSOR WIRE IACV 4P (Black) CONNECTOR SENSOR 1P (Black) CONNECTOR FUEL FEED HOSE SENSOR WIRE MOVABLE DRIVE FACE POSITION...
  • Page 58 maxiscooter-club.ru GENERAL INFORMATION MOVABLE DRIVE FACE POSITION SENSOR 3P (Black) CONNECTOR SENSOR UNIT 5P (Black) CONNECTOR THROTTLE CABLES ECT SENSOR 3P PAIR CONTROL (Gray) CONNECTOR SOLENOID VALVE 2P (Black) CONNECTOR INJECTOR 2P (Gray) CONNECTOR ALTERNATOR WIRE WATER HOSES 1-54...
  • Page 59 maxiscooter-club.ru GENERAL INFORMATION SENSOR 1P (Black) CONNECTOR RATIO MOTOR 2P (Black) CONNECTOR RIGHT CRANKCASE BREATHER HOSE REAR WHEEL SPEED SENSOR 2P (Orange) CONNECTOR DRIVEN SENSOR/VS SENSOR/EOP SWITCH/MOVABLE DRIVE FACE POSITION SENSOR 10P (Black) CONNECTOR REAR WHEEL SPEED SENSOR VS SENSOR/DRIVE PULLEY SENSOR WIRE 1-55...
  • Page 60 maxiscooter-club.ru GENERAL INFORMATION SPARK PLUG WIRE FUEL PUMP UNIT 5P (Natural) CONNECTOR FUEL FEED HOSE MAIN HARNESS GROUND CABLES SEAT LOCK RELEASE ACTUATOR 2P (Gray) CONNECTOR REAR WHEEL SPEED SENSOR 2P (Orange) CONNECTOR 1-56...
  • Page 61 maxiscooter-club.ru GENERAL INFORMATION DRIVE SENSOR/VS SENSOR/EOP SWITCH/MOVABLE DRIVE FACE POSITION SENSOR 10P (Black) CONNECTOR THROTTLE CABLES WIRE HARNESS STARTER MOTOR CABLE MOVABLE DRIVE FACE POSITION SENSOR WIRE EOP SWITCH WIRE GROUND CABLES VS SENSOR/DRIVEN PULLEY SENSOR WIRE REAR WHEEL SPEED SENSOR 2P (Orange) CONNECTOR REAR WHEEL SPEED SENSOR WIRE 1-57...
  • Page 62 maxiscooter-club.ru GENERAL INFORMATION FINAL DRIVE CASE BREATHER HOSE DRIVEN PULLEY SENSOR WIRE VS SENSOR 3P (Black) 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 DLC 4P (Red) ABS SERVICE CHECK 3P (Natural) CONNECTOR...
  • Page 63 maxiscooter-club.ru GENERAL INFORMATION RF UNIT WIRE BATTERY (–) CABLE BATTERY (+) CABLE BATTERY (–) CABLES MAIN HARNESS BATTERY (–) CABLE LICENSE LIGHT 3P (Gray) CONNECTOR TURN SIGNAL/TAIL/BRAKE LIGHT 5P (Gray) CONNECTOR LICENSE LIGHT MAIN HARNESS 1-59...
  • Page 64 maxiscooter-club.ru GENERAL INFORMATION RIGHT BRAKE/TAIL LIGHT 3P (Natural) CONNECTOR LEFT BRAKE/TAIL LIGHT 3P (Natural) CONNECTOR RIGHT REAR TURN SIGNAL LIGHT WIRE LEFT REAR TURN SIGNAL LIGHT WIRE LICENSE LIGHT 3P (Gray) CONNECTOR TURN SIGNAL/TAIL/BRAKE LIGHT 5P (Gray) CONNECTOR 1-60...

  • Page 65: Emission Control Systems

    Carbon 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.

  • Page 66: Exhaust Emission Control System

    maxiscooter-club.ru GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a pulse secondary air supply system, a three-way catalytic converter and PGM-FI system. SECONDARY AIR SUPPLY SYSTEM The pulse secondary air supply system introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port by the function of the PAIR control solenoid valve.

  • Page 67: Noise Emission Control System

    maxiscooter-club.ru GENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE EMISSION CONTROL SYSTEM IS PROHIBITED: Local law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any vehicle for the purpose of noise control prior to its sale or delivery to the ultimate customer or while it is in use;...
  • Page 68 maxiscooter-club.ru MEMO...
  • Page 69 2. TECHNICAL FEATURES CLOSED CRANKCASE SYSTEM················ 2-2 HANDLE LOCK MODULE – PCM/ECM COMMUNICATION LINE ··························· 2-6 Honda Smart Card Key System ················ 2-4 Honda S Matic System (NSS250A) ·········· 2-7...
  • Page 70 maxiscooter-club.ru TECHNICAL FEATURES CLOSED CRANKCASE SYSTEM TECHNICAL FEATURES The lubrication system of this scooter adopt the closed crankcase system. This system separates the crank room from the oil room, decrease the pumping loss of the crankshaft and balancer, and stabilize the oil surface. The engine oil pumped by the oil pump feeds separately through the oil filter and oil passage to the crankcase and cylinder head.
  • Page 71 maxiscooter-club.ru TECHNICAL FEATURES BALANCER SEPARATE TYPE METAL BEARINGS CRANK ROOM REED VALVE...
  • Page 72 SUMMARY Honda Smart Card Key System consists of following components: • Honda Smart Card Key: Each key has individual ID and transmits/receives ID code signal to/from the Handle Lock Mod- ule. • Handle Lock Module: identifies the Card Key and controls the ignition switch, seat lock and the console box lock.
  • Page 73 TECHNICAL FEATURES SEAT LOCK/CONSOLE BOX LOCK OPERATION Seat lock cannot be unlocked when the ignition switch is turned on. 1. Turn on the Honda Smart Card Key System ON/OFF switch and put SEAT LOCK HANDLE LOCK it close to the vehicle, then push the ignition switch.
  • Page 74 PCM 21P (Black) CONNECTOR HANDLE LOCK MODULE 21P (Black) CONNECTOR (PCM side/male terminals) (PCM side/male terminals) (Module side/male terminals) When the ignition switch is turned ON Honda Smart Card Key Malfunction Indicator Engine indicator Lamp (MIL) No voltage in Black/white line...
  • Page 75 Honda S Matic System (NSS250A) SUMMARY Honda S Matic System enables the selection between Automatic mode (D mode/S mode) and 7-speed mode (A mode/D mode). The Mode select switch located on the right handlebar enables the choice between the Automatic mode and the 7- speed mode.
  • Page 76 maxiscooter-club.ru TECHNICAL FEATURES A mode [Automatic shifting] A mode is the system that controls the shifting 7-speed automatically by the PCM. The PCM receives the signal from the TP, CKP, VS sensors, and shift the 7-speed automatically according to the situation. Therefore, this A mode realizes running like the manual transmission by only operating the throttle.
  • Page 77 maxiscooter-club.ru TECHNICAL FEATURES SYSTEM CONSTRUCTION METER FUSE 5 A Bl/O IGNITION SWITCH MAIN B FUSE 15 A R/Bl R/Bl BANK ANGLE ECU,IGN FUSE 10 A SENSOR ENGINE STOP RELAY Bl/O BATTERY RATIO MOTOR FUSE 30 A ENGINE STOP SWITCH MAIN R/Bl DRIVEN PULLEY SENSOR Bl/W...
  • Page 78 maxiscooter-club.ru TECHNICAL FEATURES TRANSMISSION SYSTEM FOR V-MATIC BELT DRIVE • This system consists of the following: – Ratio control motor – Reduction gear A – Reduction gear B – Movable drive face position sensor – Movable drive face position sensor shaft –...
  • Page 79 maxiscooter-club.ru 3. FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS ························ 3-2 REAR BODY UPPER COVER/REAR COMBINATION LIGHT ····························· 3-14 BODY PANEL REMOVAL CHART ·············· 3-3 LUGGAGE LOWER BOX ·························· 3-16 SERVICE INFORMATION ··························· 3-4 SCREEN GARNISH··································· 3-18 TROUBLESHOOTING ································· 3-4 FRONT CENTER COVER ·························· 3-19 TRIM CLIP····················································...

  • Page 80: Body Panel Locations

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS FRAME/BODY PANELS/EXHAUST SYSTEM (18) (13) (14) (17) (26) (10) (12) (16) (15) (22) (21) (11) (19) (24) (20) (23) (25) Right inner box (page 3-26) (14) Front seat (page 3-7) Under cover (page 3-30) (15) Front fender (page 3-30)

  • Page 81: Body Panel Removal Chart

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL REMOVAL CHART • This chart shows removal order of frame covers by means of arrow. When only removing the floor (14) Front seat side panel, open the front seat. When removing the front seat, remove the floor side panel.

  • Page 82: Service Information

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL • This section covers removal and installation of the body panels and exhaust system. • Serious burns may result if the exhaust system is not allowed to cool before components are removed or serviced. •...

  • Page 83: Trim Clip

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM TRIM CLIP TRIM CLIP A REMOVAL 1. Push the center pin of the trim clip. TRIM CLIP 2. Remove the trim clip. CENTER PIN INSTALLATION 1. Raise the center pin by spreading apart the pin ends and then push the retaining tabs back. 2.

  • Page 84: Snap Fit Clip

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM SNAP FIT CLIP REMOVAL/INSTALLATION Separate the parts by pulling the snap fit clip Make sure that the INSERTION OF THE straight out of the hole, being careful not to tilt the insertion of the clip SNAP FIT CLIP insertion of the clip.

  • Page 85: Front Seat

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM FRONT SEAT REMOVAL/INSTALLATION Remove the floor side panel (page 3-6). FRONT SEAT Remove the bolts and opener damper from the front seat. Remove the bolts and washers from the seat hinge. Remove the front seat. Install the seat, bolts and washers. Fill the opener damper joint ball Install the opener damper and bolts.

  • Page 86: Opener Damper

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM OPENER DAMPER REMOVAL/INSTALLATION Remove the front seat (page 3-7). Remove the bolt, washer and opener damper. Installation is in the reverse order of removal. OPENER DAMPER BOLT/WASHER REAR SEAT REMOVAL/INSTALLATION Open the front seat. BOSSES TABS Release the bosses of the rear seat from the grom- mets.

  • Page 87: Floor Skirt

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM FLOOR SKIRT REMOVAL/INSTALLATION Remove the floor mat (page 3-8). When removing the left floor skirt, lower the side- stand. Remove the screws and trim clip A. Release the front end tab of the floor skirt from the Be careful not to groove by carefully pulling the front end of the floor damage the tabs...

  • Page 88: Rear Body Lower Cover

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM REAR BODY LOWER COVER REMOVAL/INSTALLATION Remove the screws. Remove the rear body lower cover by slightly slid- Be careful not to ing the rear body lower cover backward and damage the tabs, unhooking the tabs, hooks and snap fit clips from hooks, snap fit clips the slots.

  • Page 89: Body Cover

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM BODY COVER REMOVAL/INSTALLATION Remove the floor side panel (page 3-6). Remove the rear body lower cover (page 3-10). Remove the screw, trim clip B and bolt/washer. Release the hooks of the body cover from the Be careful not to grooves of the rear body upper cover, luggage box damage the hooks and floor step by slightly pulling the body cover...

  • Page 90: Floor Step

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM FLOOR STEP REMOVAL/INSTALLATION Open the front seat. Remove the following: – Floor skirt (page 3-9) – Body cover (page 3-11) Remove the screws, bolt and bolt/washers. Release the front end tab and hooks of the floor step Be careful not to from the inner cover slots.

  • Page 91: Rear Spoiler

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM REAR SPOILER REMOVAL/INSTALLATION Remove the rear seat (page 3-8). SPOILER COVER Remove the screws. Carefully pull the spoiler cover out and release the tabs of the spoiler cover from the spoiler lower SCREWS cover grooves in specified sequence as shown. Remove the spoiler cover upward.

  • Page 92: Rear Body Upper Cover/Rear

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the nuts and seat lock. SEAT LOCK Remove the screws and spoiler lower cover. Assembly is in the reverse order of disassembly. SCREWS NUTS SPOILER LOWER COVER REAR BODY UPPER COVER/REAR COMBINATION LIGHT REMOVAL/INSTALLATION Remove the following: –...
  • Page 93 maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Disconnect the tail/brake light 3P and rear turn sig- SCREWS 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).

  • Page 94: Luggage Lower Box

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM LUGGAGE LOWER BOX REMOVAL/INSTALLATION • Luggage lower box can be removed/installed as an assembly of the following parts: – Luggage upper box – Rear body upper cover/rear combination light (Disconnect the turn signal/tail/brake light 5P (Gray) and license light 3P (Gray) connectors.) Remove the following: –...
  • Page 95 maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY • Luggage upper box can be removed/installed with the luggage lower box is installed in the frame. Remove the screws and luggage upper box from LUGGAGE UPPER BOX SCREWS the luggage lower box. Remove the screw and helmet wire cover by releas- ing its groove from the luggage lower box tab.

  • Page 96: Screen Garnish

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM SCREEN GARNISH REMOVAL/INSTALLATION Remove the meter visor cover, bolts, collars, wash- Do not scratch or ers and meter visor. damage the meter METER VISOR COVERS visor. METER VISOR BOLTS/COLLARS/WASHERS Remove the screw. SCREEN GARNISH SNAP FIT CLIPS Remove the screen garnish by releasing the follow- ing: –...

  • Page 97: Front Center Cover

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the screws. SCREEN GARNISH TABS Remove the front meter panel by releasing the tabs Be careful not to of the screen garnish from the holes of the front damage the tabs meter panel. and holes. Assembly is in the reverse order of disassembly.

  • Page 98: Front Lower Cover

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM FRONT LOWER COVER REMOVAL/INSTALLATION Remove the trim clips A, trim clip B and screws. Remove the front lower cover. Be careful not to damage the tabs. TRIM CLIPS A Installation is in the reverse order of removal. TABS SCREWS TRIM CLIP B...

  • Page 99: Front Side Cover

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM FRONT SIDE COVER REMOVAL/INSTALLATION Remove the following: – Screen garnish (page 3-18) – Handlebar post cover (page 3-20) – Floor skirt (page 3-9) – Front center cover (page 3-19) – Front lower cover (page 3-20) Disconnect the turn signal/position/headlight 4P (Blue, Gray) connector.

  • Page 100: Rear Meter Panel

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Disconnect the headlight 3P and front turn signal FRONT TURN SIGNAL LIGHT light 3P connectors. Disconnect the position light socket by turning it to counterclockwise. HEAD LIGHT Remove the screws, clamps and turn signal/posi- tion/headlight wire. Remove the screws and headlight.
  • Page 101 maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM Remove the screws. NSS250A shown: Disconnect the seat/console box lock release button REAR METER PANEL 4P CONNECTOR 4P (Black) and combination meter 28P (Gray) con- nectors. SCREWS Remove the rear meter panel by releasing the tabs from the grommets of the frame.

  • Page 102: Console Box

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM CONSOLE BOX REMOVAL/INSTALLATION Open the console box. RAILS Open the console box fully by pushing it forward about half of travel and pulling out the console box slowly. Push the console box lightly and slide the pin to left, then pull out the console box from the rail.
  • Page 103 maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM LEFT OUTER BOX Remove the screw and console box stay. Disconnect the console box lock cable. Remove the bolt and console box lock. Remove the screws and left outer rails. CONSOLE BOX LOCK CONSOLE BOX LOCK CABLE LEFT OUTER RAIL SCREWS BOX LOCK STAY...

  • Page 104: Right Inner Box

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM RIGHT INNER BOX REMOVAL/INSTALLATION Pull the knob and open the right inner box fully. Remove the screw, collar and right inner box. Remove the screw and outer rail from the inner RIGHT INNER BOX OUTER RAIL cover.

  • Page 105: Inner Cover

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM INNER COVER REMOVAL/INSTALLATION Remove the following: BOX ACTUATOR 2P CONNECTOR – Rear meter panel (page 3-22) – Floor step (page 3-12) TRIM CLIP B – Console box (page 3-24) Disconnect the console box lock release actuator 2P LF ANTENNA 2P CONNECTOR (Gray) and LF antenna 2P (Natural) connectors.
  • Page 106 maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY Remove the right inner box (page 3-26). Remove the console 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.
  • Page 107 maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM Disconnect the mechanical key cable. Remove the screws and key cylinder stay. Remove the E clip, cable stay, washer, set plate, key cylinder stay, washer and key cylinder. Remove the screws and fuel lid stay from the inner cover.

  • Page 108: Under Cover

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM UNDER COVER REMOVAL/INSTALLATION Remove the floor skirt (page 3-9). FUEL TANK OVERFLOW HOSE Remove the trim clip B and bolt/washers. Unhook the parking brake cable from the hooks of the under cover. BREATHER COOLANT Remove the under cover and disconnect the fuel HOSE C OVERFLOW HOSE tank overflow hose, breather hose C and radiator...

  • Page 109: Rear Fender

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER REMOVAL/INSTALLATION • Rear fender can be removed/installed as an assembly of the license light assembly. Remove the rear body lower cover (page 3-10). Disconnect the license light 3P (Gray) connector. Remove the screws, trim clips B and license light cover.

  • Page 110: Exhaust Pipe/Muffler

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST PIPE/MUFFLER REMOVAL Loosen the muffler band bolt. BOLT MUFFLER BAND Remove the muffler mounting bolts, muffler and MUFFLER gasket. BOLTS GASKET Remove the exhaust pipe joint nuts. NUTS Remove the exhaust pipe and gasket. EXHAUST PIPE/GASKET When removing the exhaust pipe protector, remove PROTECTOR the bolts and exhaust pipe protector.
  • Page 111 maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION GASKET 29 N·m (3.0 kgf·m, 21 lbf·ft) BOLTS PROTECTOR EXHAUST PIPE MUFFLER ASSEMBLY 49 N·m (5.0 kgf·m, 36 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) When removing the exhaust pipe protector, install PROTECTOR the exhaust pipe protector and tighten the bolts securely.
  • Page 112 maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM Loosely install the exhaust pipe to the cylinder head NUTS and nuts. EXHAUST PIPE/GASKET Install a new gasket to the exhaust pipe. Install the muffler band to the muffler as shown. MUFFLER BAND GASKET Loosely install the muffler mounting bolts. MUFFLER BOLTS Tighten the muffler mounting bolts, band bolt, joint...

  • Page 113: Muffler Protector/Tail Cap

    maxiscooter-club.ru FRAME/BODY PANELS/EXHAUST SYSTEM MUFFLER PROTECTOR/TAIL CAP COVER REMOVAL/INSTALLATION • Muffler protector can be removed/installed with the muffler installed in the engine. Remove the socket bolts, washers, rubbers and muffler protector. Remove the socket bolts, washers and tail cap cover. Remove the bolt/washers and tail cap cover stay from the muffler.
  • Page 114 maxiscooter-club.ru MEMO...
  • Page 115 maxiscooter-club.ru 4. MAINTENANCE SERVICE INFORMATION ··························· 4-2 BELT CASE AIR CLEANER ······················· 4-15 MAINTENANCE SCHEDULE ······················ 4-4 FINAL DRIVE OIL ······································ 4-16 FUEL LINE ··················································· 4-5 BRAKE FLUID ··········································· 4-17 THROTTLE OPERATION····························· 4-5 BRAKE PADS WEAR ································ 4-18 AIR CLEANER·············································· 4-6 BRAKE SYSTEM·······································...

  • Page 116: Service Information

    1.4 liter (1.5 US qt, 1.2 Imp qt) After disassembly 1.7 liter (1.8 US qt, 1.5 Imp qt) Recommended engine oil Honda "4-stroke motorcycle oil" or an equivalent Oil recommendation: API classification: SG or higher (except oils labeled as energy conserving on the circular...
  • Page 117 maxiscooter-club.ru MAINTENANCE TORQUE VALUES Air cleaner cover screw 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) Brake hose oil bolt 34 N·m (3.5 kgf·m, 25 lbf·ft) Brake pipe joint nut 14 N·m (1.4 kgf·m, 10 lbf·ft) Element cover bolt 12 N·m (1.2 kgf·m, 9 lbf·ft) Engine oil drain bolt 25 N·m (2.5 kgf·m, 18 lbf·ft) Apply oil to the threads.

  • Page 118: Maintenance Schedule

    ** STEERING HEAD BEARINGS 4-25 * Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechan- ically qualified. ** In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.

  • Page 119: Fuel Line

    maxiscooter-club.ru MAINTENANCE FUEL LINE Remove the luggage lower box (page 3-16). Check the fuel feed hose for deterioration, damage or leakage. Replace it if necessary. Also, check the fuel feed hose fittings for leakage. Install the luggage lower box (page 3-16). FUEL FEED HOSE THROTTLE OPERATION Check the throttle cables and replace them if they...

  • Page 120: Air Cleaner

    maxiscooter-club.ru MAINTENANCE Throttle grip freeplay can be adjusted at either end NSS250A shown: of the throttle cable. Minor adjustment is made with the upper adjuster. LOCK NUT Slide the rubber boot off the adjuster. Loosen the lock nut, turn the adjuster as required and tighten the lock nut.

  • Page 121: Crankcase Breather

    maxiscooter-club.ru MAINTENANCE CRANKCASE BREATHER Service more frequently when ridden in rain, at full throttle, or after the scooter is washed or over- turned. Service if the deposit level can be seen in the crankcase breather hose. Check the crankcase breather hose. CRANKCASE BREATHER HOSE If deposits has collected, remove the clip and crank- case breather drain plug from the crankcase...
  • Page 122 maxiscooter-club.ru MAINTENANCE Inspect or replace as described in the maintenance CENTER ELECTRODE schedule (page 4-4). Clean the spark plug electrodes with a wire brush or special plug cleaner. Check the insulator and replace the spark plug if it is cracks or damage, and the electrodes for wear, foul- ing or discoloration.

  • Page 123: Valve Clearance

    maxiscooter-club.ru MAINTENANCE VALVE CLEARANCE • Inspect and adjust the valve clearance while the engine is cold (below 35°C/95°F). • After the valve clearance inspection, check the engine idle speed (page 6-102). INSPECTION Turn the drive pulley face (crankshaft) counter clockwise and align the "T" mark on the compres- sion stroke (page 9-6).

  • Page 124: Engine Oil

    maxiscooter-club.ru MAINTENANCE Calculate the new shim thickness using the equa- Sixty-nine different tion below. thickness shims are available from A = (B – C) + D 1.200 mm A: New shim thickness thickness shim to B: Recorded valve clearance the thickest 2.900 C: Specified valve clearance mm thickness shim D: Old shim thickness...
  • Page 125 RECOMMENDED ENGINE OIL: temperature in your Honda "4-stroke motorcycle oil" or an equivalent riding area. Use the Oil recommendation: chart as a guide. API classification: SG or higher (except oils labeled as energy conserving on the...

  • Page 126: Engine Oil Filter

    maxiscooter-club.ru MAINTENANCE ENGINE OIL CHANGE INDICATOR INSPECTION • The oil change indicator appears in the display when the mileage hours on this scooter approaches the oil change interval specified on the maintenance schedule. • Reset the indicator after each oil change. To reset the indicator, press and hold the reset but- NSS250A shown: ton then ignition switch ON.

  • Page 127: Radiator Coolant

    maxiscooter-club.ru MAINTENANCE Coat a new O-ring with engine oil and install it to OIL FILTER BOSS OIL FILTER CARTRIDGE the oil filter cartridge. Apply oil to the threads of a new oil filter cartridge. Install the oil filter cartridge and tighten it to the specified torque using the special tool.

  • Page 128: Secondary Air Supply System

    maxiscooter-club.ru MAINTENANCE Tighten the radiator hose band screws as shown. Fill the recommended coolant mixture to the filler neck and bleed the air (page 7-6). After installation, check the radiator and radiator hoses for leaks. 0 – 1.0 mm (0 – 0.04 in) WATER HOSE BAND Check the radiator air passage for clogs or damage.

  • Page 129: Drive Belt

    maxiscooter-club.ru MAINTENANCE DRIVE BELT Remove the left side rear cover (page 4-15). DRIVE BELT Check the drive belt for cracks, separation, abnor- mal or excessive wear. Replace it if necessary. Measure the drive belt width (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.

  • Page 130: Final Drive Oil

    SEALING WASHER hole until it reaches the lower edge of the hole. RECOMMENDED FINAL DRIVE OIL: Honda "4-stroke motorcycle oil" or an equivalent Oil recommendation: API classification: SG or higher (except oils labeled as energy conserving on the...

  • Page 131: Brake Fluid

    maxiscooter-club.ru MAINTENANCE OIL CHANGE Remove the left side rear cover (page 4-15). OIL CHECK BOLT SEALING WASHER Support the scooter on its center stand. Remove the oil check bolt, oil drain bolt and both sealing washers then slowly turn the rear wheel. After the oil is completely drained, install the oil drain bolt with a new sealing washer and tighten it to the specified torque.

  • Page 132: Brake Pads Wear

    maxiscooter-club.ru MAINTENANCE BRAKE FLUID FILLING Remove the screws, reservoir cap, set plate and dia- RIGHT MASTER CYLINDER: phragm. CASTING LEDGE Fill the reservoir with DOT 4 brake fluid from a sealed container to the casting ledge. SET PLATE DIAPHRAGM Install the diaphragm, set plate and reservoir cap, LEFT MASTER CYLINDER: then tighten the cap screws to the specified torque.

  • Page 133: Brake System

    maxiscooter-club.ru MAINTENANCE REAR BRAKE PADS Check the brake pads for wear. WEAR LIMIT GROOVES Replace the brake pads if either pad reaches the bot- tom of wear limit groove. For the rear brake pad replacement (page 17-15) Always replace the brake pads as a set to assure even disc pressure.

  • Page 134: Brake Light Switch

    maxiscooter-club.ru MAINTENANCE Make sure that the front wheel does not turn while NSS250A shown: the rear brake lever is applied. BRAKE LIGHT SWITCH Apply the brake levers. The brake light NSS250A shown: Make sure the brake light comes on just prior to the switch on the brake brake actually being engaged.

  • Page 135: Headlight Aim

    maxiscooter-club.ru MAINTENANCE Check the clearance of the joint pin and adjusting PARKING BRAKE LEVER nut, by pushing the parking brake lever. Make sure the cut-out of the adjusting nut is seated on the joint pin. Unlock the parking brake lever by pulling it. Make sure that the rear wheel rotates smoothly.

  • Page 136: Sidestand

    maxiscooter-club.ru MAINTENANCE SIDESTAND INSPECTION Support the scooter on its center stand. Check the sidestand spring for damage or loss of tension. Check the sidestand assembly for freedom of move- ment and lubricate the sidestand pivot if necessary. SIDESTAND SPRING REMOVAL/INSTALLATION Remove the left floor skirt (page 3-9).

  • Page 137: Suspension

    maxiscooter-club.ru MAINTENANCE SUSPENSION FRONT Check the action of the forks by operating the front brakes and compressing the front suspension sev- eral times. Check the entire assembly for signs of leaks, dam- age or loose fasteners. Replace damaged components which cannot be Loose, worn or repaired (page 15-18).

  • Page 138: Wheels/Tires

    maxiscooter-club.ru MAINTENANCE WHEELS/TIRES FRONT WHEEL Support the scooter on its center stand. NSS250A shown: Jack up the scooter to raise the front wheel off the ground. Hold the front fork and move the front wheel side- ways forcefully to see if the front wheel bearings are worn.

  • Page 139: Steering Head Bearings

    maxiscooter-club.ru MAINTENANCE Check the tires for cuts, embedded nails, or other NSS250A shown: damage. Check the front wheel for trueness: – Front: (page 15-14) – Rear: (page 16-7) RECOMMENDED TIRE SIZE: FRONT 110/90 – 13 M/C 55P Tire size REAR 140/70 –...
  • Page 140 maxiscooter-club.ru MEMO...
  • Page 141 maxiscooter-club.ru 5. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ·········· 5-2 OIL STRAINER ············································ 5-6 SERVICE INFORMATION ··························· 5-3 OIL PRESSURE RELIEF VALVE ················· 5-7 TROUBLESHOOTING ································· 5-4 REED VALVE ·············································· 5-8 OIL PRESSURE INSPECTION····················· 5-5 OIL PUMP ··················································· 5-9...

  • Page 142: Lubrication System Diagram

    maxiscooter-club.ru LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM LUBRICATION SYSTEM CAMSHAFT MAIN JOURNAL BEARING OIL JET MAIN JOURNAL BEARING CRANKSHAFT EOP SWITCH OIL FILTER CARTRIDGE OIL PUMP OIL PRESSURE RELIEF VALVE REED VALVE OIL STRAINER/SCREEN...

  • Page 143: Service Information

    1.4 liter (1.5 US qt, 1.2 Imp qt) – After disassembly 1.7 liter (1.8 US qt, 1.5 Imp qt) – Recommended engine oil Honda "4-stroke motorcycle oil" or an equivalent Oil recommendation: API classification: SG or higher (except oils labeled as energy con- –...

  • Page 144: Troubleshooting

    maxiscooter-club.ru LUBRICATION SYSTEM TROUBLESHOOTING Engine oil level too low • Oil consumption • External oil leak • Worn piston rings • Improperly installed piston rings (page 10-7) • Worn cylinder • Worn valve stem seals • Worn valve guide Low oil pressure •...

  • Page 145: Oil Pressure Inspection

    maxiscooter-club.ru LUBRICATION SYSTEM OIL PRESSURE INSPECTION • For EOP switch inspection (page 22-25) EOP SWITCH SCREW Start the engine and warm it up. Stop the engine. Remove the EOP switch cover. Remove the screw and disconnect the EOP switch wire. Remove the EOP switch from the crankcase.

  • Page 146: Oil Strainer

    maxiscooter-club.ru LUBRICATION SYSTEM OIL STRAINER REMOVAL Remove the right crankcase cover (page 13-4). OIL STRAINER SCREEN Remove the oil strainer screen and oil strainer. OIL STRAINER INSPECTION Check the oil strainer screen for damage or clogs. INSTALLATION Install the oil strainer into the crankcase. OIL STRAINER •...

  • Page 147: Oil Pressure Relief Valve

    maxiscooter-club.ru LUBRICATION SYSTEM OIL PRESSURE RELIEF VALVE REMOVAL Separate the crankcase (page 14-5). OIL PRESSURE RELIEF VALVE Remove the oil pressure relief valve, O-ring from the crankcase. O-RING DISASSEMBLY/INSPECTION/ ASSEMBLY Check the operation of the oil pressure relief valve PISTON SNAP RING by pushing on the piston.

  • Page 148: Reed Valve

    maxiscooter-club.ru LUBRICATION SYSTEM INSTALLATION Coat a new O-ring with oil and install it to the OIL PRESSURE RELIEF VALVE groove of the oil pressure relief valve. Install the oil pressure relief valve into the left crank- case. Assemble the crankcase (page 14-21). O-RING REED VALVE REMOVAL...

  • Page 149: Oil Pump

    maxiscooter-club.ru LUBRICATION SYSTEM OIL PUMP REMOVAL Remove the right crankcase cover (page 13-4). DRIVEN SPROCKET COVER Remove the bolt and driven sprocket cover. BOLT Remove the bolt and oil pump driven sprocket from The oil pump driven BOLT (Left-hand threads) the oil pump.
  • Page 150 maxiscooter-club.ru LUBRICATION SYSTEM Remove the washer, oil pump shaft and drive pin. WASHER OIL PUMP SHAFT Remove the inner and outer rotors from the oil INNER ROTOR pump body. Wash all parts with a high flash point or non-flam- mable solvent. OUTER ROTOR INSPECTION •...
  • Page 151 maxiscooter-club.ru LUBRICATION SYSTEM BODY CLEARANCE Measure the clearance between the oil pump body BODY CLEARANCE: and outer rotor with a feeler gauge. SERVICE LIMIT: 0.35 mm (0.014 in) SIDE CLEARANCE Measure the side clearance using a straight edge SIDE CLEARANCE: and feeler gauge.
  • Page 152 maxiscooter-club.ru LUBRICATION SYSTEM Apply oil to the oil pump inner rotor and outer rotor INNER ROTOR GROOVES whole surface. Install the outer rotor into the oil pump body. Install the inner rotor into the outer rotor with its drive pin groove facing the oil pump cover. OUTER ROTOR Apply oil to the oil pump shaft rolling area.
  • Page 153 maxiscooter-club.ru LUBRICATION SYSTEM Apply oil to the drive chain whole surface and Align DRIVE CHAIN driven sprocket teeth. Set the drive chain over the driven sprocket, and install the driven sprocket to the oil pump. • Install the driven sprocket with its "OUT" mark facing out.
  • Page 154 maxiscooter-club.ru MEMO...
  • Page 155 ECT SENSOR ············································ 6-92 SENSOR UNIT POWER LINE INSPECTION BANK ANGLE SENSOR ··························· 6-92 (NSS250A)················································· 6-22 ECM (NSS250S) ······································· 6-95 DTC TROUBLESHOOTING (NSS250S) ··· 6-24 PCM (NSS250A) ······································· 6-99 DTC TROUBLESHOOTING (NSS250A) ··· 6-36 ENGINE IDLE SPEED······························ 6-102 MIL TROUBLESHOOTING (NSS250S) ···· 6-48 IACV ························································...

  • Page 156: Component Location

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) COMPONENT LOCATION FUEL SYSTEM (PGM-FI) 11 N·m (1.1 kgf·m, 8 lbf·ft)

  • Page 157: Service Information

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) SERVICE INFORMATION GENERAL • Be sure to relive the fuel pressure while the engine is OFF. • Before disconnecting fuel feed hose, relieve pressure from the system by disconnecting the quick connect fitting (page 6-71). • Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bend, result- ing in loss of vehicle control.
  • Page 158 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) TOOLS Fuel pressure gauge Pressure gauge manifold Hose attachment, 9 mm/9 mm 07406-0040004 07ZAJ-S5A0111 07ZAJ-S5A0120 Hose attachment, 6 mm/9 mm Attachment joint, 6 mm/9 mm SCS connector 07ZAJ-S5A0130 07ZAJ-S5A0150 070PZ-ZY30100 ECM test harness 33P Test probe 070MZ-MCA0100 07ZAJ-RDJA110...
  • Page 159 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) PGM-FI SYMPTOM TROUBLESHOOTING When the scooter has one of these symptoms, check the DTC or MIL blinking, refer to the DTC index (page 6-19) and begin the appropriate troubleshooting procedure. If there are no DTC/MIL blinking stored in the PCM/ECM memory, do the diag- nostic procedure for the symptom, in sequence listed below, until you find the cause.

  • Page 160: Pgm-Fi System Location

    FUEL SYSTEM (PGM-FI) PGM-FI SYSTEM LOCATION NSS250S ENGINE STOP SWITCH THROTTLE BODY: – MAP SENSOR COMBINATION METER HANDLE LOCK – TP SENSOR MODULE – IAT SENSOR – IACV REGULATOR/RECTIFIER BANK ANGLE SENSOR INJECTOR FAN MOTOR FUEL PUMP UNIT IGNITION COIL...
  • Page 161 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) NSS250A ENGINE STOP SWITCH THROTTLE BODY: – MAP SENSOR COMBINATION METER HANDLE LOCK – TP SENSOR MODULE – IAT SENSOR – IACV REGULATOR/RECTIFIER BANK ANGLE SENSOR INJECTOR FAN MOTOR FUEL PUMP UNIT IGNITION COIL PAIR CONTROL SOLENOID VALVE ECT SENSOR SIDESTAND FUSE/RELAY BOX:...

  • Page 162: Pgm-Fi System Diagram

    FUEL SYSTEM (PGM-FI) PGM-FI SYSTEM DIAGRAM NSS250S Bl/W METER FUSE 5 A Bl/O IGNITION SWITCH MAIN B FUSE 15 A R/Bl R/Bl ECU,IGN FUSE 10 A FAN MOTOR FUSE 15 A BANK ANGLE Bl/O Bu/O SENSOR FUEL PUMP FUSE 10 A...
  • Page 163 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) NSS250A Bl/W METER FUSE 5 A Bl/O IGNITION SWITCH MAIN B FUSE 15 A R/Bl R/Bl ECU,IGN FUSE 10 A FAN MOTOR FUSE 15 A BANK ANGLE Bl/O Bu/O SENSOR FUEL PUMP FUSE 10 A ENGINE STOP BATTERY Bl/Y ENGINE STOP...

  • Page 164: Pgm-Fi Connector Locations

    FUEL SYSTEM (PGM-FI) PGM-FI CONNECTOR LOCATIONS NSS250S NOTE 1: Remove the left body cover (page 3-11). ECM 33P (Black) CONNECTOR NOTE 2: Remove the battery cover (page 19-6). DLC 4P (Red) 6-10...
  • Page 165 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) NOTE 3: Remove the luggage lower box (page 3-16). SENSOR UNIT 5P (Black) CONNECTOR IACV 4P (Black) CONNECTOR SENSOR (Black) CONNECTOR INJECTOR 2P (Gray) CONNECTOR ECT SENSOR 3P (Gray) CONNECTOR 6-11...

  • Page 166: Nss250A

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) NSS250A NOTE 1: Remove the left body cover (page 3-11). PCM 21P (Black) CONNECTOR (B) PCM 33P (Black) CONNECTOR (A) NOTE 2: Remove the battery cover (page 19-6). DLC 4P (Red) 6-12...
  • Page 167 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) NOTE 3: Remove the luggage lower box (page 3-16). IACV 4P (Black) CONNECTOR SENSOR UNIT 5P (Black) CONNECTOR SENSOR (Black) CONNECTOR INJECTOR 2P (Gray) CONNECTOR ECT SENSOR 3P (Gray) CONNECTOR 6-13...

  • Page 168: General Troubleshooting

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) PGM-FI TROUBLESHOOTING INFORMATION GENERAL TROUBLESHOOTING Intermittent Failure The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the MIL does not come on, check for poor contact or loose pins at all connectors related to the circuit that of the troubleshooting. If the MIL was on, but then went out, the original problem may be intermittent.
  • Page 169 Connect the HDS pocket tester to the DLC. Turn the ignition switch ON, check the DTC and freeze data. • Stored data indicates the engine (and Honda S Matic System) con- ditions when the first malfunction was detected. PCM/ECM reset The HDS can reset the PCM/ECM data including the DTC, stored data and some learning memory.
  • Page 170 If the PCM/ECM has any DTC in its memory, the MIL will start blinking. ERASING DTC • When erasing the PGM-FI DTC as follows, the Honda S Matic DTC would also be erased at the same time. Connect the HDS Pocket Tester to the DLC (page 6-15).
  • Page 171 TOOL: Test probe 07ZAJ-RDJA110 TEST PROBE TEST HARNESS CONNECTION (NSS250S) Remove the left body cover (page 3-11). Turn the ignition switch OFF. Disconnect the ECM 33P (Black) connector. 33P (Black) CONNECTOR Connect the test harness between the main wire harness and ECM.
  • Page 172 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) Connect the test harness between the main wire harness and PCM. TOOL: ECM test harness 33P 070MZ-MCA0100 TEST HARNESS TEST HARNESS TERMINAL LAYOUT The PCM/ECM connector terminals are numbered as shown in the PCM/ECM 33P CONNECTOR illustration.
  • Page 173 • Loose or poor contact of the IACV connector rough idling (29) A: 6-47 A: 6-66 • IACV or its circuit malfunction PCM/ECM EEPROM malfunction • Engine operates normally S: 6-36 33-2 (– ) – A: 6-48 • S: NSS250S • A: NSS250A 6-19...
  • Page 174 FUEL SYSTEM (PGM-FI) SENSOR UNIT POWER LINE INSPECTION (NSS250S) BEFORE DTC TROUBLESHOOTING • When the DTC displays 1-2, 8-1 and 9-2, check the following before DTC troubleshooting. • Before starting the inspection, check for loose or poor contact on the sensor unit 5P (Black) and ECM 33P (Black) connectors.
  • Page 175 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) BEFORE MIL TROUBLESHOOTING • When the MIL blinks 1, 8 and 9 times, check the following before MIL troubleshooting. • Before starting the inspection, check for loose or poor contact on the sensor unit 5P (Black) and ECM 33P (Black) connectors.
  • Page 176 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 4. Sensor Unit Input Voltage Line Short Circuit Inspection Check the continuity between the sensor unit 5P SENSOR UNIT 5P CONNECTOR connector of the wire side and ground. (Wire side/female terminals) CONNECTION: Yellow/red – Ground Is there continuity? –...
  • Page 177 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 3. Sensor Unit Input Voltage Line Short Circuit Inspection Check the continuity between the sensor unit 5P SENSOR UNIT 5P CONNECTOR connector of the wire side and ground. (Wire side/female terminals) CONNECTION: Yellow/red – Ground Is there continuity? –...

  • Page 178: Dtc Troubleshooting (Nss250S)

    CONNECTION: Yellow/red – Ground Is there continuity? – Short circuit in Yellow/red wire Yellow/red – Intermittent failure DTC TROUBLESHOOTING (NSS250S) DTC 1-1 (MAP SENSOR LOW VOLTAGE) 1. MAP Sensor System Inspection Turn the ignition switch ON and engine stop switch " ".
  • Page 179 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 3. MAP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. SENSOR UNIT 5P CONNECTOR Disconnect the sensor unit 5P (Black) connector. (Wire side/female terminals) Check the continuity between the sensor unit 5P connector of the wire side and ground. CONNECTION: Yellow/orange –...
  • Page 180 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 3. MAP Sensor System Inspection 2 Turn the ignition switch OFF. SENSOR UNIT 5P CONNECTOR Disconnect the sensor unit 5P (Black) connector. (Wire side/female terminals) Connect the sensor unit 5P connector terminals at the wire side with a jumper wire. CONNECTION: Yellow/orange –...
  • Page 181 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 3. ECT Sensor Resistance Inspection Turn the ignition switch OFF. ECT SENSOR (Sensor side/male terminals) Measure the resistance at the ECT sensor termi- nals. CONNECTION: Pink/white – Green/orange STANDARD: 2.3 – 2.6 kΩ (20°C/68°F) Is the resistance within 2.3 – 2.6 k Ω (20 ° C/68 ° F)? –...
  • Page 182 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 2. ECT Sensor Inspection Turn the ignition switch OFF. ECT SENSOR 3P CONNECTOR Disconnect the ECT sensor 3P (Gray) connector. (Wire side/female terminals) Connect the ECT sensor terminals of the wire side with a jumper wire. CONNECTION: Pink/white –...
  • Page 183 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 3. TP Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. SENSOR UNIT 5P CONNECTOR Disconnect the sensor unit 5P (Black) connector. (Wire side/female terminals) Disconnect the ECM 33P (Black) connector. Check the continuity at the White/red wire between the sensor unit 5P and ECM 33P con- nectors.
  • Page 184 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 2. TP Sensor Inspection Check that the TP sensor voltage increases con- tinuously when moving the throttle from fully closed to fully opened using the data list menu of the HDS pocket tester. Does the voltage increase continuously? –...
  • Page 185 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 3. IAT Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. SENSOR UNIT 5P CONNECTOR Check the continuity between the sensor unit 5P (Wire side/female terminals) connector terminal of the wire side and ground. CONNECTION: White/blue –...
  • Page 186 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 4. IAT Sensor Line Inspection Turn the ignition switch OFF. ECM 33P CONNECTOR Disconnect the ECM 33P (Black) connector. (Wire side/female terminals) Check the continuity between the ECM 33P and sensor unit 5P connectors of the wire side. TOOL: Test probe 07ZAJ-RDJA110...
  • Page 187 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 4. Injector Signal Line Short Circuit Inspection Check the continuity between the injector 2P INJECTOR 2P CONNECTOR connector at the wire side and ground. (Wire side/female terminals) CONNECTION: Pink/blue – Ground Is there continuity? – Short circuit in Pink/blue wire –...
  • Page 188 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 2. O Sensor Open Circuit Inspection Turn the ignition switch OFF. ECM 33P CONNECTOR Disconnect the ECM 33P (Black) connector. (Wire side/female terminals) Black/orange Disconnect the O sensor 1P (Black) connector. Check the continuity between the O sensor 1P and ECM 33P connectors of the wire side.
  • Page 189 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) DTC 29-1 (IACV) • Before starting the inspection, check for loose or poor contact on the IACV 4P (Black) connector and recheck the DTC. 1. Recheck DTC Erase the DTC’s (page 6-16). Turn the ignition switch ON and engine stop switch "...

  • Page 190: Dtc Troubleshooting (Nss250A)

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 4. IACV Resistance Inspection Measure the resistance at the IACV 4P connector IACV 4P CONNECTOR terminals. (IACV side/male terminals) CONNECTION: Light green/red Gray/red Gray/red – Light green/red Brown/red – Black/red STANDARD: 110 – 150 Ω (25°C/77°F) Is the resistance within 110 –...
  • Page 191 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 3. MAP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. SENSOR UNIT 5P CONNECTOR Disconnect the sensor unit 5P (Black) connector. (Wire side/female terminals) Check the continuity between the sensor unit 5P connector of the wire side and ground. CONNECTION: Yellow/orange –...
  • Page 192 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 3. MAP Sensor System Inspection 2 Turn the ignition switch OFF. SENSOR UNIT 5P CONNECTOR Disconnect the sensor unit 5P (Black) connector. (Wire side/female terminals) Connect the sensor unit 5P connector terminals at the wire side with a jumper wire. CONNECTION: Yellow/orange –...
  • Page 193 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 3. ECT Sensor Resistance Inspection Turn the ignition switch OFF. ECT SENSOR Measure the resistance at the ECT sensor termi- nals. CONNECTION: Pink/white – Green/orange STANDARD: 2.3 – 2.6 kΩ (20°C/68°F) Is the resistance within 2.3 – 2.6 k Ω (20 ° C/68 ° F)? –...
  • Page 194 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 2. ECT Sensor Inspection Turn the ignition switch OFF. ECT SENSOR 3P CONNECTOR Disconnect the ECT sensor 3P (Gray) connector. (Wire side/female terminals) Connect the ECT sensor terminals of the wire side with a jumper wire. CONNECTION: Pink/white –...
  • Page 195 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 3. TP Sensor Output Line Open Circuit Inspection Turn the ignition switch OFF. SENSOR UNIT 5P CONNECTOR Disconnect the sensor unit 5P (Black) connector. (Wire side/female terminals) Disconnect the PCM 33P (Black) connector. Check the continuity at the White/red wire between the sensor unit 5P and PCM 33P con- nectors.
  • Page 196 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) DTC 8-2 (TP SENSOR HIGH VOLTAGE) 1. TP Sensor System Inspection Turn the ignition switch ON and engine stop switch " ". Check the TP sensor with the HDS pocket tester. Is about 5 V indicated? –...
  • Page 197 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 2. IAT Sensor Inspection Turn the ignition switch OFF. Disconnect the sensor unit 5P (Black) connector. Turn the ignition switch ON and engine stop switch " ". Check the IAT sensor with the HDS pocket tester. Is about 0 V indicated? –...
  • Page 198 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 4. IAT Sensor Line Inspection Turn the ignition switch OFF. PCM 33P CONNECTOR Disconnect the PCM 33P (Black) connector. (Wire side/female terminals) Check the continuity between the PCM 33P and sensor unit 5P connectors of the wire side. TOOL: Test probe 07ZAJ-RDJA110...
  • Page 199 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 4. Injector Signal Line Short Circuit Inspection Check the continuity between the injector 2P INJECTOR 2P CONNECTOR connector at the wire side and ground. (Wire side/female terminals) CONNECTION: Pink/blue – Ground Is there continuity? – Short circuit in Pink/blue wire –...
  • Page 200 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 2. O Sensor Open Circuit Inspection Turn the ignition switch OFF. PCM 33P CONNECTOR Disconnect the PCM 33P (Black) connector. (Wire side/female terminals) Disconnect the O sensor 1P (Black) connector. Black/orange Check the continuity between the O sensor 1P and PCM 33P connectors of the wire side.
  • Page 201 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) DTC 29-1 (IACV) • Before starting the inspection, check for loose or poor contact on the IACV 4P (Black) connector and recheck the DTC. 1. Recheck DTC Erase the DTC’s (page 6-16). Turn the ignition switch ON and engine stop switch "...

  • Page 202: Mil Troubleshooting (Nss250S)

    Is the DTC 33-2 indicated? – Replace the PCM with a known good one, and recheck. – Intermittent failure MIL TROUBLESHOOTING (NSS250S) MIL 1 BLINK (MAP SENSOR) 1. Sensor Unit Power Line Inspection Check the sensor unit power line inspection (page 6-22).
  • Page 203 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 3. MAP Sensor Output Voltage Inspection 2 Turn the ignition switch OFF. SENSOR UNIT 5P CONNECTOR Disconnect the sensor unit 5P (Black) connector. (Wire side/female terminals) Turn the ignition switch ON and engine stop switch " ". Measure the voltage at the wire side.
  • Page 204 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) MIL 7 BLINKS (ECT SENSOR) • Before starting the inspection, check for loose or poor contact on the ECT sensor 3P (Gray) con- nector and recheck the MIL blinking. 1. ECT Sensor Output Voltage Inspection Connect the test harness to the ECM 33P (Black) TEST HARNESS PIN BOX connector (page 6-17).
  • Page 205 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 4. ECT Sensor Short Circuit Inspection Check the continuity between the ECT sensor ECT SENSOR 3P CONNECTOR connector of the wire side and ground. (Wire side/female terminals) CONNECTION: Pink/white – Ground Is there continuity? – Short circuit in Pink/white wire –...
  • Page 206 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 3. TP Sensor Output Line Short Circuit Inspection Turn the ignition switch OFF. SENSOR UNIT 5P CONNECTOR Disconnect the ECM 33P (Black) connector. (Wire side/female terminals) Disconnect the sensor unit 5P (Black) connector. Check the continuity between the sensor unit 5P connector of the wire side and ground.
  • Page 207 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 3. IAT Sensor Input Voltage Inspection Turn the ignition switch OFF. SENSOR UNIT 5P CONNECTOR Disconnect the sensor unit 5P (Black) connector. (Wire side/female terminals) Turn the ignition switch ON and engine stop switch " ". Measure the voltage at the sensor unit 5P con- nector of the wire side.
  • Page 208 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 6. IAT Sensor Resistance Inspection Turn the ignition switch OFF. TEST HARNESS PIN BOX Connect the sensor unit 5P (Black) connector. Measure the resistance at the test harness termi- nals. CONNECTION: 14 – 4 STANDARD: 1.0 – 1.3 kΩ (40°C/104°F) Is the resistance within 1.0 –...
  • Page 209 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 3. Injector Signal Line Short Circuit Inspection Check the continuity between the injector 2P INJECTOR 2P CONNECTOR connector of the wire side and ground. (Wire side/female terminals) CONNECTION: Pink/blue – Ground Is there continuity? – Short circuit in Pink/blue wire –...
  • Page 210 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 2. O Sensor Open Circuit Inspection Connect the test harness to the ECM 33P connec- SENSOR 1P CONNECTOR tor (page 6-17). (Wire side/female terminal) Disconnect the O sensor 1P (Black) connector. Check the continuity between the test harness and O sensor 1P connector of the wire side.
  • Page 211 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) MIL 29 BLINKS (IACV) • Before starting the inspection, check for loose or poor contact on the IACV 4P (Black) connector and recheck the MIL blinking. 1. IACV Short Circuit Inspection Turn the ignition switch OFF. IACV 4P CONNECTOR Check the continuity between the IACV 4P con- (Wire side/female terminals)

  • Page 212: Mil Troubleshooting (Nss250A)

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) MIL TROUBLESHOOTING (NSS250A) 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? – GO TO STEP 2. – Replace or repair of the abnormal cir- cuit.
  • Page 213 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 5. MAP Sensor Output Line Open Circuit Inspection 2 Check the continuity between the test harness TEST HARNESS PIN BOX and sensor unit 5P connector of the wire side. CONNECTION: 8 – Yellow/orange Yellow/orange Is there continuity? –...
  • Page 214 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 3. ECT Sensor Open Circuit Inspection Turn the ignition switch OFF. ECT SENSOR 3P CONNECTOR Check the continuity between the test harness (Wire side/female terminals) and ECT sensor 3P connector of the wire side. CONNECTION: 6 – Pink/white 10 –...
  • Page 215 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) MIL 8 BLINKS (TP SENSOR) 1. Sensor Unit Power Line Inspection Check the sensor unit power line inspection (page 6-22). Is the sensor unit power line normal? – GO TO STEP 2. – Replace or repair the abnormal circuit. 2.
  • Page 216 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) MIL 9 BLINKS (IAT SENSOR) 1. Sensor Unit Power Line Inspection Check the sensor unit power line inspection (page 6-22). Is the sensor unit power line normal? – GO TO STEP 2. – Replace or repair the abnormal circuit. 2.
  • Page 217 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 5. IAT Sensor Voltage Output Line Open Circuit Inspection Check the continuity between the sensor unit 5P SENSOR UNIT 5P CONNECTOR connector of the wire side and test harness. (Wire side/female terminals) CONNECTION: 7 – White/blue Is there continuity? –...
  • Page 218 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 2. Injector Signal Line Open Circuit Inspection Connect the test harness to the PCM 33P connec- TEST HARNESS PIN BOX tor (page 6-17). check the continuity between the test harness and injector 2P connector of the wire side. CONNECTION: 2 –...
  • Page 219 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) MIL 21 BLINKS (O SENSOR) Do not reuse O sensor cord, if the O sensor cap is disconnected, replace the O sensor cord with a new one. • Before starting the inspection, check for loose or poor contact on the O sensor 1P (Black) connec- tor and recheck the MIL blinking.
  • Page 220 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 4. O Sensor Inspection Replace the O sensor and O sensor cord with a known good one (page 6-107). Disconnect the test harness and connect the PCM 33P (Black) connector. Turn the ignition switch ON and engine stop switch "...

  • Page 221: Mil Circuit Inspection

    • If it does not function, check the combination meter (page 22-10). • If it functions properly, check as follows: MIL circuit inspection with test probe NSS250S: Turn the ignition switch OFF. Remove the left body cover (page 3-11). Disconnect the PCM/ECM 33P (Black) connector.
  • Page 222 (Black) connector (page 6-17). Ground the PCM/ECM 33P (Black) connector termi- nal of the wire side connector with a jumper wire. CONNECTION: NSS250S: 18 – Ground NSS250A: 31 – Ground (18) Turn the ignition switch ON and engine stop switch "...
  • Page 223 • If it does not function, check the combination meter (page 22-10). • If it functions properly, check as follows: MIL and DLC circuit inspection with test probe NSS250S: Turn the ignition switch OFF. Remove the left body cover (page 3-11). Disconnect the PCM/ECM 33P (Black) connector.
  • Page 224 Connect the test harness to the PCM/ECM 33P TEST HARNESS PIN BOX (Black) connector (page 6-17). Check the continuity between the test harness and ground. CONNECTION: NSS250S: 15 – Ground 18 – Ground NSS250A: 25 – Ground (15) (18) 31 – Ground...

  • Page 225: Fuel Line Inspection

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) FUEL LINE INSPECTION FUEL PRESSURE RELIEVING • Before disconnecting the fuel feed hose, relieve pressure from the system as follows. 1. Remove the luggage lower box (page 3-16). FUEL PUMP UNIT 5P CONNECTOR Temporarily install the battery. •...
  • Page 226 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 5. To prevent damage and keep foreign matter out, PLASTIC BAG PIPE cover the disconnected connector and pipe end with the plastic bags. CONNECTOR INJECTOR SIDE 1. Relieve the fuel pressure (page 6-71). QUICK CONNECT FITTING 2.
  • Page 227 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 5. To prevent damage and keep foreign matter out, PLASTIC BAG PIPE cover the disconnected connector and pipe end with the plastic bags. CONNECTOR QUICK CONNECT FITTING INSTALLATION • Always replace the retainer of the quick connect fitting when the fuel feed hose is disconnected.
  • Page 228 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 4. Make sure the connection is secure and that the RUBBER CAP locking pawls are firmly locked into place; check visually and by pulling the connector. 5. Make sure the rubber cap is in place (between the retainer tabs).
  • Page 229 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) FUEL PRESSURE INCREASING 1. Connect the battery negative (–) cable. FUEL PUMP UNIT 5P CONNECTOR 2. Install the clamp and connect the fuel pump unit 5P (Natural) connector. 3. Turn the ignition switch ON and engine stop switch "...

  • Page 230: Fuel Pump Unit

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) FUEL FLOW INSPECTION Disconnect the quick connect fitting from the fuel FUEL PUMP RELAY JUMPER WIRE pump unit (page 6-71). Remove the fuse/relay box cover (page 3-17). Temporarily install the connect the fuel pump unit 5P (Natural) connector and negative (–) cable. Turn the ignition switch OFF.
  • Page 231 – MAIN B fuse (15 A) – Fuel 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...
  • Page 232 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) INSTALLATION • When installing the fuel pump unit, put the mat- ing surface of the fuel tank on a level surface. Clean the mating surface of the fuel tank and fuel FUEL PUMP Align pump unit. Apply oil to the lip surface of a new packing inside.

  • Page 233: Fuel Pump Relay/Engine Stop

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) FUEL PUMP RELAY/ENGINE STOP RELAY INSPECTION Remove the luggage lower box (page 3-16). FUSE BOX COVER Turn the ignition switch OFF. Remove the screws and fuse/relay box from the fuse box cover. SCREW Remove the RF unit and fuse/relay box cover. RF UNIT FUSE/RELAY BOX COVER Remove the following:...

  • Page 234: Fuel Tank

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) FUEL TANK REMOVAL/INSTALLATION Remove the under cover (page 3-30). CLAMP Remove the inner cover (page 3-27). Disconnect the fuel connect fitting from the fuel pump unit (page 6-71). Remove the following: – Bolts – Clamp BOLTS –...
  • Page 235 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) Disconnect the right crankcase breather hose from RIGHT CRANKCASE BREATHER HOSE the air cleaner housing. Loosen the connecting boot band screw and remove the air cleaner housing. SCREW INSTALLATION Install the connecting boot of the air cleaner hous- RIGHT CRANKCASE BREATHER HOSE ing to the throttle body.

  • Page 236: Throttle Body

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) THROTTLE BODY REMOVAL Before disconnecting fuel feed hose, relieve pres- sure from the system by disconnecting the quick connect fitting. Disconnect the quick connect fitting from the fuel LOCK NUTS pump unit (page 6-71). Remove the luggage lower box (page 3-16). Loosen the throttle cable lock nuts and disconnect the throttle cables from the throttle drum and cable guide.
  • Page 237 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) DISASSEMBLY/ASSEMBLY • The throttle body is factory pre-set. Do not disas- semble in a way other than shown in this man- ual. • Do not snap the throttle valve from full open to full close after the throttle cable has been removed.
  • Page 238 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) INSTALLATION Install the throttle body to the insulator by aligning its lug with the slot in the insulator. Align Connect the connecting boot to the throttle body THROTTLE BODY CONNECTING BOOT and tighten the connecting boot band screw to the BAND SCREW specified torque.

  • Page 239: Intake Pipe

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) INTAKE PIPE REMOVAL Remove the injector (page 6-86). SCREW Loosen the throttle body side of the insulator band screw. Remove the bolts, stay and intake pipe. INTAKE PIPE BOLTS STAY Remove the insulator A and O-rings. INSULATOR A/O-RINGS DISASSEMBLY Loosen the screw and remove the insulator B from...

  • Page 240: Injector

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) INSTALLATION Coat new O-rings with engine oil and install the O- O-RINGS rings to both side of the insulator A grooves. Place the insulator A between the cylinder head and intake pipe. INSULATOR A Install the intake pipe, stay and bolts. BOLTS Tighten the intake pipe mounting bolts securely.
  • Page 241 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) Remove the bolts, stay and injector/joint assembly BOLTS STAY from the intake pipe. INJECTOR/JOINT ASSEMBLY Remove the injector from the injector joint, O-ring INJECTOR JOINT and seal ring. INJECTOR SEAL RING O-RING INSTALLATION Coat a new O-ring and new seal ring with engine oil. INJECTOR JOINT Install the O-ring and seal ring, being careful not to Replace the O-ring...

  • Page 242: Sensor Unit

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) Install the injector/joint assembly to the intake pipe, BOLTS STAY being careful not to damage the seal ring. Install and tighten the bolts securely. INJECTOR/JOINT ASSEMBLY Install the clamp to the stay. STAY Connect the injector 2P (Gray) connector. Install the luggage lower box (page 3-16).
  • Page 243 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) INSTALLATION Install a new O-ring to the throttle body groove If the O-ring is not SENSOR UNIT O-RING properly. installed properly, the idle air will leaks Install the sensor unit to the throttle body by align- and engine idle ing the clip of the TP sensor and boss of the throttle speed will be...
  • Page 244 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) THROTTLE VALVE FULLY CLOSED POSITION RESET PROCEDURE • Make sure that the DTCs are not stored in PCM/ ECM. If the DTCs are stored in PCM/ECM, the throttle valve fully closed position reset mode won’t start. •...
  • Page 245 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 10.Check if the MIL blinks. If the MIL begins short blink (0.3 seconds), the throttle valve fully closed position is reset. • If the MIL stays lit, the throttle valve fully closed position is not reset, repeat the reset procedure from step 3.

  • Page 246: Ect Sensor

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) ECT SENSOR REMOVAL/INSTALLATION Drain the coolant to a suitable container (page 7-6). ECT SENSOR Remove the luggage lower box (page 3-16). Remove the intake pipe (page 6-85). Disconnect the ECT sensor 3P (Gray) connector. Remove the ECT sensor and sealing washer. Replace the ECT sensor while the engine is cold.
  • Page 247 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) Place the bank angle sensor is horizontal (normal If you check this position) as shown, and ignition switch ON and test, the ignition 49° bank angle position engine stop switch " ". switch OFF, then turn the ignition The bank angle sensor is normal if the engine stop switch ON and relay clicks and power supply is closed.
  • Page 248 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 3. Ground Line Inspection Turn the ignition switch OFF. BANK ANGLE SENSOR 3P CONNECTOR Check the continuity between the bank angle (Wire side/female terminals) sensor 3P (Black) connector of wire side and ground. CONNECTION: Green/orange – Ground Is there continuity? Green/orange –...

  • Page 249: Ecm (Nss250S)

    FUEL SYSTEM (PGM-FI) ECM (NSS250S) POWER/GROUND LINE INSPECTION WITH TEST PROBE • Before starting the inspection, check for loose or poor contact on the ECM 33P (Black) connector and recheck the MIL blinking. Engine does not start (MIL no blinks) 1.
  • Page 250 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 4. Engine Stop Relay Inspection 2 Turn the ignition switch OFF. FUSE/RELAY BOX Jump the engine stop relay connector terminals. (Wire side/female terminals) CONNECTION: Black – Black/white Turn the ignition switch ON and engine stop JUMPER WIRE switch "...
  • Page 251 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 2. Ground Line Inspection Turn the ignition switch OFF. TEST HARNESS PIN BOX Check the continuity between the test harness and ground. CONNECTION: 9 – Ground 10 – Ground 2 – Ground Is there continuity? (10) –...
  • Page 252 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 4. Engine Stop Relay Inspection 2 Turn the ignition switch OFF. FUSE/RELAY BOX Jump the engine stop relay connector terminals. (Wire side/female terminals) CONNECTION: Black – Black/white Turn the ignition switch ON and engine stop JUMPER WIRE switch "...

  • Page 253: Pcm (Nss250A)

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) PCM (NSS250A) POWER/GROUND LINE INSPECTION WITH TEST PROBE • Before starting the inspection, check for loose or poor contact on the PCM 33P (Black) connector and recheck the MIL blinking. Engine does not start (MIL no blinks) 1.
  • Page 254 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 4. Engine Stop Relay Inspection 2 Turn the ignition switch OFF. FUSE/RELAY BOX (Wire Jump the engine stop relay connector terminals. side/female terminals) CONNECTION: Black – Black/white Turn the ignition switch ON and engine stop JUMPER WIRE switch "...
  • Page 255 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) 2. Ground Line Inspection Turn the ignition switch OFF. TEST HARNESS PIN BOX Check the continuity between the test harness and ground. CONNECTION: 3 – Ground 4 – Ground 22 – Ground (22) Is there continuity? –...

  • Page 256: Engine Idle Speed

    FUEL SYSTEM (PGM-FI) REMOVAL/INSTALLATION • When replacing the PCM, the Honda S Matic must be reset the movable drive face position and learn it to PCM (page 24-61). Remove the left body cover (page 3-11). BOLT/WASHERS Disconnect the following: –...

  • Page 257: Iacv

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) IACV INSPECTION The IACV is installed on the throttle body and is operated by the step motor. When the ignition switch is turned ON and engine stop switch " ", the IACV operates for a few seconds. Check the step motor operating (beep) sound with the ignition switch turned ON and engine stop switch "...
  • Page 258 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) INSTALLATION Turn the slide valve clockwise until lightly seated on valve body. Install the IACV into the throttle body while aligning SLIT GUIDE PIN the valve slit with the guide pin in the throttle body. Align IACV Install the IACV retainer while aligning its groove SET PLATE...

  • Page 259: Secondary Air Supply System

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) SECONDARY AIR SUPPLY SYSTEM SYSTEM INSPECTION Support the scooter on its center stand. Remove the air cleaner element (page 4-6). Check that the secondary air intake port is clean and free of carbon deposits. If the port is carbon fouled, check the PAIR control check valve (page 6-105).
  • Page 260 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) INSPECTION Remove the PAIR control solenoid valve (page 6- PAIR SOLENOID VALVE 105). Check that the air should flow (A) to (B), only when the 12 V battery is connected to the PAIR control solenoid valve terminals. Air should not flow when the battery is connected.

  • Page 261: O 2 Sensor

    maxiscooter-club.ru FUEL SYSTEM (PGM-FI) Check the PAIR check valve for damage. REED STOPPER Check the valve seat for crack, damage or deterio- rate. Replace it if necessary. Replace the PAIR check valve if the rubber seat is cracked, deteriorated or damaged. VALVE SEAT SENSOR •...
  • Page 262 maxiscooter-club.ru FUEL SYSTEM (PGM-FI) Remove the O sensor from the cylinder head. SENSOR INSTALLATION • Do not use an impact wrench while removing or installing the O sensor, or it may be damaged. Install and hand tighten an O sensor onto the cylin- der head.
  • Page 263 maxiscooter-club.ru 7. COOLING SYSTEM SYSTEM FLOW PATTERN ························· 7-2 THERMOSTAT ·········································· 7-10 SERVICE INFORMATION ··························· 7-3 WATER PUMP ·········································· 7-11 TROUBLESHOOTING ································· 7-4 RADIATOR ················································ 7-14 SYSTEM TESTING······································ 7-5 RADIATOR RESERVE TANK ···················· 7-17 COOLANT REPLACEMENT ························ 7-6 FAN CONTROL RELAY ···························· 7-17...

  • Page 264: System Flow Pattern

    maxiscooter-club.ru COOLING SYSTEM SYSTEM FLOW PATTERN COOLING SYSTEM RADIATOR CAP THERMOSTAT SIPHON HOSE WATER PUMP RESERVE TANK RESERVE TANK OVERFLOW HOSE...

  • Page 265: Service Information

    maxiscooter-club.ru COOLING SYSTEM SERVICE INFORMATION GENERAL Removing the radiator cap while 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. Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage.

  • Page 266: Troubleshooting

    maxiscooter-club.ru COOLING SYSTEM TOOLS Bearing remover head, 14 mm Bearing remover shaft, 15 mm Remover weight 07WMC-KFG0100 07936-KC10100 07741-0010201 Driver Attachment, 24 x 26 mm Mechanical seal driver 07749-0010000 07746-0010700 07PMD-KBP0100 TROUBLESHOOTING Engine temperature too high • Insufficient coolant • Air in system •...

  • Page 267: System Testing

    maxiscooter-club.ru COOLING SYSTEM SYSTEM TESTING COOLANT (HYDROMETER TEST) Remove the left floor side panel (page 3-6). FILLER NECK BOLT Remove the bolt and pull the filler neck out from the inner cover open area. Remove the radiator cap. he engine must be RADIATOR CAP cool before removing the...

  • Page 268: Coolant Replacement

    maxiscooter-club.ru COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the radiator cap (page 7-5). TESTER Wet the sealing surfaces of the cap, then install the cap onto tester. Pressurize the radiator cap using the tester. Replace the radiator cap if it does not hold pressure, or if relief pressure is too high or too low.
  • Page 269 maxiscooter-club.ru COOLING SYSTEM REPLACEMENT/AIR BLEEDING Support the scooter on its center stand. BOLT/SEALING WASHER Remove the following: The engine must be cool before – Floor mat (page 3-8) removing the – Radiator cap (page 7-5) cooling system. – Left floor skirt (page 3-9) Drain the coolant from the system by removing the drain bolt, sealing washer and radiator cap.
  • Page 270 maxiscooter-club.ru COOLING SYSTEM Fill the reserve tank to the upper level line. UPPER LINE Remove the luggage box mat (page 3-16). MAINTENANCE LID Remove the maintenance lid. Remove the air bleed bolt and sealing washer. AIR BLEED BOLT/SEALING WASHER Fill the coolant from the filler neck until the coolant FILLER NECK BOLT HOLE starts flowing from the bolt hole.
  • Page 271 maxiscooter-club.ru COOLING SYSTEM Stop filling and install the air bleed bolt with a new AIR BLEED BOLT/SEALING WASHER sealing washer. Fill the system with the recommended coolant through the filler opening up to the filler neck. Install the maintenance lid. MAINTENANCE LID Install the luggage box mat (page 3-16).

  • Page 272: Thermostat

    maxiscooter-club.ru COOLING SYSTEM THERMOSTAT REMOVAL/INSTALLATION Drain the coolant from the system (page 7-7). COVER Remove the luggage lower box (page 3-16). Remove the bolt and water hose clamp. Remove the bolts and thermostat cover. BOLTS BOLT/CLAMP Remove the thermostat. Align BLEED HOLE Installation is in the reverse order of removal.

  • Page 273: Water Pump

    maxiscooter-club.ru COOLING SYSTEM WATER PUMP MECHANICAL SEAL INSPECTION Check the bleed hole of the water pump for signs of coolant leakage. • A small amount of coolant weeping from the bleed hole is normal. • Make sure that there are no continuous coolant leakage from the bleed hole while operating the engine.
  • Page 274 maxiscooter-club.ru COOLING SYSTEM MECHANICAL SEAL REPLACEMENT Remove the mechanical seal using special tools. BEARING REMOVER MECHANICAL SEAL TOOLS: Bearing remover head, 14 mm 07WMC-KFG0100 Bearing remover shaft, 15 mm 07936-KC10100 Remover weight 07741-0010201 REMOVER WEIGHT REMOVER SHAFT Remove the oil seal. BLEED HOLE PASSAGE Blow the inspection hole in the crankcase cover with compressed air to clean it.
  • Page 275 maxiscooter-club.ru COOLING SYSTEM Install the thrust washer to the water pump shaft. Install the thrust WATER PUMP SHAFT THRUST WASHER Install the water pump shaft into the right crankcase washer with the cover. chamfered (rolled) edge facing the Check the pump shaft for smooth rotation. pump shaft tab.

  • Page 276: Radiator

    maxiscooter-club.ru COOLING SYSTEM RADIATOR REMOVAL/INSTALLATION Drain the coolant from the system (page 7-7). Remove the following: – Right floor step (page 3-12) – Left floor skirt (page 3-9) – Front center cover (page 3-19) – Front lower cover (page 3-20) Disconnect the fan motor 2P (Brown) connector.
  • Page 277 maxiscooter-club.ru COOLING SYSTEM Installation is in the reverse order of removal. • Route the hoses properly (page 1-21). • When installing the radiator, align the tabs of the radiator with the grommet of the frame. Fill and bleed the cooling system (page 7-6). Align Align DISASSEMBLY...
  • Page 278 maxiscooter-club.ru COOLING SYSTEM ASSEMBLY RADIATOR 8.5 N·m (0.9 kgf·m, 6.3 lbf·ft) 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft) COOLING FAN 2.7 N·m (0.3 kgf·m, 2 lbf·ft) SHROUD FAN MOTOR Apply locking agent to the fan motor threads. Install the cooling fan to the cooling fan motor by aligning the cut-out of the cooling fan with the cut- out of the fan motor shaft and tighten the nut to the specified torque.

  • Page 279: Radiator Reserve Tank

    maxiscooter-club.ru COOLING SYSTEM Install the fan motor/shroud assembly to the radia- BOLT/WASHERS tor. Install the bolt/washers and tighten them to the specified torque. TORQUE: 8.5 N·m (0.9 kgf·m, 6.3 lbf·ft) Install the radiator (page 7-14). FAN MOTOR/SHROUD ASSEMBLY RADIATOR RESERVE TANK Drain the coolant from the system (page 7-7).
  • Page 280 maxiscooter-club.ru MEMO...
  • Page 281 maxiscooter-club.ru 8. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ·························· 8-2 ENGINE REMOVAL ···································· 8-4 SERVICE INFORMATION ··························· 8-3 ENGINE INSTALLATION···························· 8-9...
  • Page 282 ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION ENGINE REMOVAL/INSTALLATION NSS250A shown: 59 N·m (6.0 kgf·m, 44 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) NSS250S: NSS250S: 39 N·m (4.0 kgf·m, 29 lbf·ft)
  • Page 283 – Water pump (page 7-11) – Camshaft (page 9-8) – Cylinder head (page 9-11) – Cylinder/Piston (page 10-4) – NSS250S: Drive pulley (page 11-11) – NSS250A: Drive pulley (page 11-18) – Final reduction (page 12-6) – Alternator (page 13-7) – Starter clutch (page 13-9) •...

  • Page 284: Engine Removal

    maxiscooter-club.ru ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil (page 4-11). BOLT HOSE CLAMP Drain the coolant (page 7-7). Remove the following: – Luggage lower box (page 3-16) – Spark plug cap (page 4-7) – Muffler (page 3-32) Relieve the fuel pressure and remove the fuel feed hose from the injector side (page 6-71).
  • Page 285 ENGINE REMOVAL/INSTALLATION Disconnect the sub-harness connector. NSS250A shown: 10P (Black) – NSS250S: Sub-harness 4P (Black) connector CONNECTOR – NSS250A: Sub-harness 10P (Black) connector GROUND CABLES Disconnect the rear wheel speed sensor 2P (Orange) NSS250A: connector. Uncover the terminal cover.
  • Page 286 maxiscooter-club.ru ENGINE REMOVAL/INSTALLATION Loosen the hose band screw and disconnect the BOLT HOSE BAND BOLT/CLAMP water hose from the thermostat cover. Remove the following: – Bolt, water hose clamp – Bolt, spark plug wire clamp – Spark plug cap CLAMP SPARK PLUG CAP Remove the rear shock absorber lower mounting LOWER MOUNTING BOLTS...
  • Page 287 maxiscooter-club.ru ENGINE REMOVAL/INSTALLATION Remove the nut, washer and pull out engine hanger Support the frame NUT/WASHER ENGINE HANGER BOLT bolt. and engine using a jack or other Remove the engine from the frame. adjustable support to ease of engine hanger bracket bolt removal.
  • Page 288 maxiscooter-club.ru ENGINE REMOVAL/INSTALLATION Remove the nuts, bolts, and engine hanger bracket. NUTS/BOLTS ENGINE HANGER BRACKET Check the engine hanger bracket bushings for wear, deterioration or damage. BUSHINGS ENGINE HANGER BRACKET BUSHINGS Check the tension rod bushings for wear, deteriora- BUSH RUBBERS tion or damage.

  • Page 289: Engine Installation

    maxiscooter-club.ru ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION • Before installing the engine, route the wires, hoses, and cables properly (page 1-21). 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 COLLAR TENSION ROD 59 N·m (6.0 kgf·m,...
  • Page 290 maxiscooter-club.ru ENGINE REMOVAL/INSTALLATION Loosely install the tension rod and nut. TENSION ROD Install the collar to the engine facing its flange to left. COLLAR FLANGE Set the engine to the frame and install the engine Support the engine NUT/WASHER ENGINE HANGER BOLT mounting bolt.
  • Page 291 maxiscooter-club.ru ENGINE REMOVAL/INSTALLATION Loosely install the rear shock absorber lower LOWER MOUNTING BOLTS mounting bolts. Support the scooter and retract the center stand. BRACKET BOLTS/NUTS Hold the engine hanger bolt and tighten the nut to the specified torque. TORQUE: 59 N·m (6.0 kgf·m, 44 lbf·ft) Hold the engine hanger bracket bolt and tighten the nuts to the specified torque.
  • Page 292 GROUND CABLES Cover the terminal cover. Connect the rear wheel speed sensor 2P (Orange) NSS250A: connector. 2P (Orange) Connect the sub-harness connector. CONNECTOR – NSS250S: Sub-harness 4P (Black) connector – NSS250A: Sub-harness 10P (Black) connector CABLE COVER BOLTS 8-12...
  • Page 293 maxiscooter-club.ru ENGINE REMOVAL/INSTALLATION Connect the PAIR control solenoid valve 2P (Black) 3P (Black) CONNECTOR connector. 2P (Black) CONNECTOR Install the alternator/CKP sensor wire to the clamp. Connect the alternator 3P (Black), CKP sensor 2P (Red) connectors. 2P (Red) CONNECTOR CLAMP Connector the water hoses to the water pump HOSE BAND cover.
  • Page 294 maxiscooter-club.ru MEMO...
  • Page 295 maxiscooter-club.ru 9. CYLINDER HEAD/VALVES COMPONENT LOCATION ·························· 9-2 CYLINDER HEAD DISASSEMBLY ··········· 9-13 SERVICE INFORMATION ··························· 9-3 VALVE GUIDE REPLACEMENT ··············· 9-15 TROUBLESHOOTING ································· 9-5 VALVE SEAT INSPECTION/ REFACING················································· 9-16 CYLINDER COMPRESSION TEST·············· 9-6 CYLINDER HEAD ASSEMBLY ················· 9-19 POSITIONING THE PISTON AT TDC (Top Dead Center) ON THE COMPRESSION CYLINDER HEAD INSTALLATION···········...

  • Page 296: Component Location

    maxiscooter-club.ru CYLINDER HEAD/VALVES COMPONENT LOCATION CYLINDER HEAD/VALVES 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)

  • Page 297: Service Information

    maxiscooter-club.ru CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL • This section covers service of the cylinder head, valves, rocker arms and camshaft. • The cylinder head and valves can be serviced with the engine installed in the frame. • When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original loca- tions.
  • Page 298 maxiscooter-club.ru CYLINDER HEAD/VALVES TOOLS Universal holder Valve spring compressor Valve spring compressor attach- 07725-0030000 07757-0010000 ment 07959-KM30101 Valve guide driver, 4.3 mm Valve guide driver Valve guide reamer, 4.5 mm 07HMD-ML00101 07743-0020000 07HMH-ML00101 Cutter holder Seat cutter, 29 mm (45° IN) Flat cutter, 24.5 mm (45°...

  • Page 299: Troubleshooting

    maxiscooter-club.ru CYLINDER HEAD/VALVES Interior cutter, 24 mm (60° EX) 070PH-Z0D0100 TROUBLESHOOTING • Engine top-end problems usually affect engine performance. These problem can be diagnosed by a compression test or by tracing engine noises to the top-end with a sounding rod or stethoscope. •...

  • Page 300: Cylinder Compression Test

    maxiscooter-club.ru CYLINDER HEAD/VALVES CYLINDER COMPRESSION TEST Warm up the engine to normal operating tempera- COMPRESSION GAUGE ture. Stop the engine and remove the spark plug cap and spark plug (page 4-7). Install a compression gauge into the spark plug hole. Open the throttle all the way and crank the engine To avoid discharging with the starter until the gauge reading stops rising.

  • Page 301: Cylinder Head Cover Removal

    maxiscooter-club.ru CYLINDER HEAD/VALVES The index line on the cam sprocket must be flush Align with the cylinder head surface as shown. If the index line on the cam sprocket is not flush with the cylinder head surface, rotate the crankshaft one full turn (360°) and align the "T"...

  • Page 302: Rocker Arm Removal

    maxiscooter-club.ru CYLINDER HEAD/VALVES CAM SPROCKET/CAMSHAFT/ROCKER ARM REMOVAL CAM SPROCKET REMOVAL Remove the cylinder head cover (page 9-7). SEALING BOLT/WASHER Remove the sealing bolt, washer and spring from the cam chain tensioner lifter. • The sealing bolt can be removed with the throttle body is installed.
  • Page 303 maxiscooter-club.ru CYLINDER HEAD/VALVES Remove the bolt and stopper plate. BOLT STOPPER PLATE Remove the camshaft while pressing the rocker arm CAMSHAFT to the valve side. Remove the rocker arm shafts, side springs, and ROCKER ARM SHAFT rocker arms. • Be sure to mark the rocker arm shafts and rocker arms so they can be installed in their original positions.
  • Page 304 maxiscooter-club.ru CYLINDER HEAD/VALVES CAMSHAFT Turn the outer race of the camshaft bearing with CAMSHAFT BEARING your finger. The bearing should turn smoothly and quietly. Also check that the bearing inner race fits tightly on the camshaft. Replace the camshaft assembly if the outer race does not turn smoothly, quietly, or if the inner race fits loosely on the camshaft.

  • Page 305: Cylinder Head Removal

    maxiscooter-club.ru CYLINDER HEAD/VALVES ROCKER ARM/SHAFT Check the rocker arm, rocker arm shaft sliding sur- Check the cam ROCKER ARMS faces for wear or damage. lobes of the camshaft if the Check the contacting surface of the rocker arms and sliding surface of shims for wear or damage.
  • Page 306 maxiscooter-club.ru CYLINDER HEAD/VALVES Remove the bolts and O sensor connector/fuel feed BOLTS STAY hose stay. Remove the insulator. INSULATOR Disconnect the water hose from the cylinder head. WATER HOSE Loosen the cylinder bolts. 9 mm BOLT/WASHERS CYLINDER HEAD Remove the cylinder head 6 mm bolts. Remove the cylinder head 9 mm bolt/washers.

  • Page 307: Cylinder Head Disassembly

    maxiscooter-club.ru CYLINDER HEAD/VALVES Remove the cam chain guide. CAM CHAIN GUIDE CYLINDER HEAD DISASSEMBLY Remove the following: VALVE COMPRESSOR – ECT sensor (page 6-92) – Spark plug (page 4-7) – Thermostat (page 7-10) – O sensor (page 6-107) – Cylinder head (page 9-11) Remove the valve spring cotters using the valve To prevent loss of spring compressor.
  • Page 308 maxiscooter-club.ru CYLINDER HEAD/VALVES Check the cylinder head for warpage with a straight edge and feeler gauge. SERVICE LIMIT: 0.05 mm (0.002 in) VALVE SPRING Check the valve springs for fatigue or damage. Measure the valve spring free length. SERVICE LIMIT: IN/EX: 35.6 mm (1.40 in) VALVE/VALVE GUIDE Check that the valve moves smoothly in the guide.

  • Page 309: Valve Guide Replacement

    maxiscooter-club.ru CYLINDER HEAD/VALVES Measure each valve guide I.D. and record it. SERVICE LIMIT: IN/EX: 4.54 mm (0.179 in) Subtract each valve stem O.D. from the correspond- ing guide I.D. to obtain the stem-to-guide clearance. SERVICE LIMITS: IN: 0.08 mm (0.003 in) EX: 0.09 mm (0.004 in) If the stem-to-guide clearance exceeds the service Inspect and reface...

  • Page 310: Valve Seat Inspection

    maxiscooter-club.ru CYLINDER HEAD/VALVES Ream new valve guides after installation. VALVE GUIDE REAMER Insert the reamer from the combustion chamber Take care not to tilt side of the head and also always rotate the reamer or lean the reamer clockwise. in the guide while reaming.

  • Page 311: Refacing

    maxiscooter-club.ru CYLINDER HEAD/VALVES Inspect the valve seat face. The valve seat contact should be within the speci- fied width and even all around the circumference. STANDARD: 0.90 – 1.10 mm (0.035 – 0.043 in) SERVICE LIMIT: 1.5 mm (0.06 in) If the valve seat width is not within specification, reface the valve seat (page 9-17).
  • Page 312 maxiscooter-club.ru CYLINDER HEAD/VALVES Using a 45° seat cutter, remove any roughness or Reface the seat ROUGHNESS with a 45 ° cutter irregularities from the seat. whenever a valve TOOLS: guide is replaced. Seat cutter, 29 mm (45° IN) 07780-0010300 Seat cutter, 24.5 mm (45° EX) 07780-0010100 Cutter holder 07781-0010600...

  • Page 313: Cylinder Head Assembly

    maxiscooter-club.ru CYLINDER HEAD/VALVES After cutting the seat, apply lapping compound to HAND-LAPPING TOOL the valve face, and lap the valve using light pres- sure. • Excessive lapping pressure may deform or dam- age the seat. • Change the angle of the lapping tool frequently to prevent uneven seat wear.

  • Page 314: Cylinder Head Installation

    maxiscooter-club.ru CYLINDER HEAD/VALVES Install the valve springs with the tightly wound coils facing the combustion chamber. Install the spring retainer. Install the valve spring cotters using spring com- Grease the cotters VALVE COMPRESSOR pressor. to ease installation. To prevent loss of TOOLS: tension, do not Valve spring compressor...
  • Page 315 maxiscooter-club.ru CYLINDER HEAD/VALVES Install the dowel pins and a new gasket onto the cyl- GASKET inder. DOWEL PINS Route the cam chain through the cylinder head and 9 mm BOLT/WASHERS CYLINDER HEAD install the cylinder head onto the cylinder. Install new cylinder head 9 mm bolt/washers. Tighten the 9 mm bolt/washers in a crisscross pat- tern in two or three steps to the specified torque.

  • Page 316: Cam Sprocket/Camshaft/Rocker Arm Installation

    maxiscooter-club.ru CYLINDER HEAD/VALVES Install the O sensor connector/fuel feed hose stay BOLTS STAY and bolt. Tighten the bolts securely. Install the O sensor cord to the clamp. SENSOR CORD Connect the O sensor 1P (Black) connector. Install the following: – Cam sprocket (page 9-22) –...
  • Page 317 maxiscooter-club.ru CYLINDER HEAD/VALVES Apply molybdenum oil solution to the camshaft CAMSHAFT CAM LOBE cam surface and sliding surfaces. SURFACES Install the camshaft while pressing the rocker arms to the valve side. Clean the cam stopper plate bolt threads, then apply BOLT STOPPER PLATE locking agent to the cam stopper plate bolt threads...
  • Page 318 maxiscooter-club.ru CYLINDER HEAD/VALVES Clean the cam sprocket bolt threads, then apply CAM SPROCKET BOLTS locking agent to the cam sprocket bolt threads (coat- ing 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)). Install the cam sprocket bolts to the cam sprocket and tighten the bolts to the specified torque.
  • Page 319 maxiscooter-club.ru CYLINDER HEAD/VALVES CYLINDER HEAD COVER INSTALLATION Check that the rubber seal is in good condition, replace it if necessary. Install the rubber seal to the groove of the cylinder head cover. RUBBER SEAL Apply liquid sealant (Three Bond 1211 or equiva- lent) to the cylinder head cover semi-circular cut-out as shown.
  • Page 320 maxiscooter-club.ru CYLINDER HEAD/VALVES Install the bolts and tighten them to the specified torque. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) BOLTS Install the following: BOLT CLAMP – 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.
  • Page 321 maxiscooter-club.ru 10. CYLINDER/PISTON COMPONENT LOCATION ························ 10-2 CYLINDER/PISTON REMOVAL ··············· 10-4 SERVICE INFORMATION ························· 10-3 CYLINDER/PISTON INSTALLATION······· 10-7 TROUBLESHOOTING ······························· 10-3 10-1...
  • Page 322 maxiscooter-club.ru CYLINDER/PISTON COMPONENT LOCATION CYLINDER/PISTON 10-2...
  • Page 323 maxiscooter-club.ru CYLINDER/PISTON SERVICE INFORMATION GENERAL • This section covers maintenance of the cylinder and piston. • The cylinder and piston can be serviced with the engine installed in the frame. • Be careful not to damage mating surfaces when removing the cylinder. •...

  • Page 324: Cylinder Removal

    maxiscooter-club.ru CYLINDER/PISTON CYLINDER/PISTON REMOVAL CYLINDER REMOVAL Remove the following: BOLT – Cylinder head (page 9-11) – PAIR check valve (page 6-106) Remove the bolts and EOP switch wire stay. STAY Remove the bolt and cylinder. CYLINDER BOLTS Remove the gasket and dowel pins. DOWEL PINS Remove and clean off any gasket material from the Be careful not to...
  • Page 325 maxiscooter-club.ru CYLINDER/PISTON Clean carbon deposits from the ring grooves with a Be careful not to PISTON OLD PISTON RING ring that will be discarded. damage the piston ring grooves. • Never use a wire brush, it will scratch the grooves. GROOVES INSPECTION PISTON RING...
  • Page 326 maxiscooter-club.ru CYLINDER/PISTON Measure the piston pin hole I.D. PISTON SERVICE LIMIT: 17.04 mm (0.671 in) Measure the piston pin O.D. at three points. SERVICE LIMIT: 16.96 mm (0.668 in) Calculate the piston-to-piston pin clearance. SERVICE LIMIT: 0.02 mm (0.001 in) PISTON PIN CONNECTING ROD Measure the connecting rod small end I.D.

  • Page 327: Piston Ring Installation

    maxiscooter-club.ru CYLINDER/PISTON CYLINDER/PISTON INSTALLATION PISTON RING INSTALLATION Apply oil to the ring grooves. Carefully install the piston rings into the piston ring Be careful not to MARK grooves with the marks (top and second) facing up. damage the piston TOP RING and rings.

  • Page 328: Cylinder Installation

    maxiscooter-club.ru CYLINDER/PISTON Install new piston pin clips. • Make sure the piston pin clips are seated in the piston grooves. • Do not align the piston pin clip end gap with the piston cutout. CUTOUT PISTON PISTON PIN CLIP CYLINDER INSTALLATION Blow out the oil and water passages of the cylinder DOWEL PINS with compressed air.
  • Page 329 11. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH COMPONENT LOCATION ························ 11-2 DRIVE PULLEY (NSS250S) ···················· 11-11 SERVICE INFORMATION ························· 11-4 DRIVE PULLEY (NSS250A) ···················· 11-18 TROUBLESHOOTING ······························· 11-6 CLUTCH/DRIVEN PULLEY····················· 11-27 LEFT CRANKCASE COVER ······················ 11-7 11-1...
  • Page 330 DRIVE PULLEY/DRIVEN PULLEY/CLUTCH COMPONENT LOCATION DRIVE PULLEY/DRIVEN PULLEY/CLUTCH 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) 11-2...
  • Page 331 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH 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) 11-3...
  • Page 332 • NSS250A: If any of the following services (the procedures which could alter the relative position of the movable drive face position sensor and the movable drive pulley assembly) have been performed, perform the Honda S Matic System initial setting procedure (page 24-61).
  • Page 333 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH TOOLS Socket wrench, 39 x 41 mm Clutch spring compressor Universal holder 07GMA-KS40100 07LME-GZ40201 07725-0030000 Remover weight Bearing remover handle Bearing remover set, 20 mm 07741-0010201 07936-3710100 07936-3710600 Bearing remover set, 25 mm Bearing remover set, 30 mm Driver 07936-ZV10100 07936-8890300...
  • Page 334 • Broken driven face spring Engine stalls or scooter creeps • Broken clutch shoe spring Poor acceleration • NSS250A: Improperly movable drive pulley face position (Honda S Matic System problem) Poor performance at high speed or lack of power • Worn drive belt •...

  • Page 335: Left Crankcase Cover

    maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH LEFT CRANKCASE COVER REMOVAL Remove the left side rear cover (page 4-15). BOLTS LEFT SIDE FRONT COVER Remove the left floor step (page 3-12). Remove the socket bolts and left side front cover. Unhook the wires from the clamps. WIRES CLAMP Unhook the rear wheel speed sensor wire from the...
  • Page 336 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH BEARING INSPECTION/ REPLACEMENT INSPECTION Turn the inner race of the bearing with your finger. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the left crankcase cover. Replace the bearing if the inner race does not turn smoothly, quietly, or if the outer race fits in the left crankcase cover.
  • Page 337 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Install the snap ring to the groove of the crankcase SNAP RING cover. • 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 element of the belt case air cleaner (page 4-15).
  • Page 338 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Coat new O-rings with oil and install them to each O-RINGS O-RINGS collar groove. Fill the crankshaft collar groove with 0.10 g (0.004 oz) of molybdenum disulfide paste. Apply molybdenum disulfide paste to the drive shaft collar groove. Temporarily install the left crankcase cover and then LEFT CRANKCASE COVER remove it.
  • Page 339 TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) 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). UNIVERSAL HOLDER Hold the drive pulley face with a special tool and loosen the drive face bolt.
  • Page 340 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Remove the drive pulley face. DRIVE PULLEY FACE Remove the drive belt. DRIVE BELT Remove the movable drive pulley face/drive face DRIVE FACE BOSS boss (ramp plate) assembly. DRIVE PULLEY FACE/RAMP PLATE DISASSEMBLY Remove the drive pulley face boss from the mov- BOSS able drive pulley face/ramp plate assembly.
  • Page 341 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Remove the dust seal. DUST SEAL Remove the ramp plate and slide pieces from the SLIDE PIECE RAMP PLATE movable drive pulley face. DRIVE PULLEY FACE Remove the weight rollers from the movable drive WEIGHT ROLLER pulley face.
  • Page 342 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH SLIDE PIECE Check the slide pieces for wear or damage. SLIDE PIECE WEIGHT ROLLER Check the weight rollers for wear or damage. WEIGHT ROLLER Measure the weight roller O.D. SERVICE LIMIT: 22.5 mm (0.89 in) MOVABLE DRIVE PULLEY FACE Measure the movable drive pulley face bushing I.D.
  • Page 343 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH ASSEMBLY • Avoid getting grease or oil on the drive belt and movable drive pulley face in order to prevent belt slippage. • Do not apply grease to the movable drive pulley face and weight rollers. SLIDE PIECE WEIGHT ROLLER MOVABLE DRIVE PULLEY FACE...
  • Page 344 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Install the slide pieces and ramp plate into the mov- SLIDE PIECE RAMP PLATE able drive pulley face. DRIVE PULLEY FACE Apply grease to a new movable drive pulley dust Do not apply grease seal lips. to the movable drive pulley face.
  • Page 345 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Set the drive belt onto the drive pulley face boss. DRIVE BELT Install the drive pulley face onto the crankshaft by DRIVE PULLEY FACE aligning the splines. Apply oil to new O-rings and install them to the O-RINGS grooves of the collar.
  • Page 346 DRIVE PULLEY FACE Remove the drive belt and drive pulley face boss A. When the drive belt DRIVE BELT is replaced, perform the Honda S Matic System initial setting procedure (page 24-61). BOSS A Remove the reduction gear B and movable drive REDUCTION GEAR B pulley assembly together.
  • Page 347 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH INSPECTION DRIVE BELT Check the drive belt for cracks, separation or abnor- 25.5 mm (1.00 in) DRIVE BELT mal or excessive wear. Measure the drive belt width. SERVICE LIMIT: 25.5 mm (1.00 in) Replace the drive belt if necessary. SLIDE PIECE Check the slide pieces for roughness, wear or dam- SLIDE PIECES...
  • Page 348 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MOVABLE DRIVE PULLEY ASSEMBLY Check the teeth of the screw gear for wear or dam- SCREW GEAR STOPPER ARM age. Replace the screw gear if necessary. Hold the slide pieces of the stopper arm and turn the screw holder with your hand.
  • Page 349 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Drive a new bearing into the holder squarely until it DRIVER is fully seated, using special tools. TOOLS: Driver 07749-0010000 Attachment, 52 x 55 mm 07746-0010400 Pilot, 22 mm 07746-0041000 ATTACHMENT/PILOT BEARING Install the snap ring to the screw holder groove. SNAP RING •...
  • Page 350 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Remove the socket bolts and screw holder. SOCKET BOLTS SCREW HOLDER Remove the O-ring from the screw gear. O-RING Remove the socket bolt and stopper plate. STOPPER PLATE SOCKET BOLT Remove the screw gear by turning it counterclock- SCREW GEAR DUST SEAL wise.
  • Page 351 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Remove the socket bolts, stopper arm and O-ring. SOCKET BOLTS DRIVE PULLEY FACE BOSS B Remove the drive pulley face boss B. Remove the oil seal. STOPPER ARM/O-RING OIL SEAL Check the movable drive face spline collar for wear SPLINE COLLAR or damage.
  • Page 352 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Install the drive pulley face boss B. OIL SEAL STOPPER ARM Coat a new oil seal with oil and install it to the mov- Be careful not to able drive pulley face. get the lubricant on the movable drive Coat a new O-ring with oil and install it to the stop- pulley face.
  • Page 353 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Coat a new O-ring with oil and install it to the screw DUST SEAL gear. Install the screw gear holder and socket bolts. SOCKET BOLTS Tighten the socket bolts to the specified torque. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) SCREW HOLDER Coat a new O-ring with oil and install it to the mov- SPLINE COLLAR...
  • Page 354 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Install the reduction gear B and movable drive pul- REDUCTION GEAR B ley face assembly as a set. DRIVE PULLEY FACE ASSEMBLY Install the drive pulley face boss A. DRIVE BELT Install the drive belt onto the movable drive pulley face assembly.
  • Page 355 Universal holder 07725-0030000 TORQUE: 83 N·m (8.5 kgf·m, 61 lbf·ft) Install the ratio control gear holder (page 24-54). Install the left crankcase cover (page 11-9). Perform the Honda S Matic System initial setting procedure (page 24-61). UNIVERSAL HOLDER CLUTCH/DRIVEN PULLEY REMOVAL Remove the left crankcase cover (page 11-7).
  • Page 356 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH DISASSEMBLY/INSPECTION CLUTCH/DRIVEN PULLEY DISASSEMBLY Set the clutch/driven pulley assembly onto a special CLUTCH/DRIVEN PULLEY ASSEMBLY tool by aligning the bosses with the holes in the clutch. TOOL: Clutch spring compressor 07LME-GZ40201 CLUTCH SPRING COMPRESSOR Hold the clutch spring compressor in a vise. SOCKET WRENCH Compress the clutch/driven pulley assembly and To prevent loss of...
  • Page 357 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Remove the shoe springs and clutch shoes from the CLUTCH SHOES drive plate. • If the clutch shoes are replaced, always replace them as a set. SPRINGS Remove the damper rubbers from the drive plate. DAMPER RUBBERS DRIVEN PULLEY DISASSEMBLY Remove the seal collar.
  • Page 358 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Remove the O-rings and oil seals from the movable OIL SEALS driven pulley face. O-RINGS DRIVEN FACE BEARING REPLACEMENT Remove the needle bearing using special tools. REMOVER WEIGHT NEEDLE BEARING TOOLS: Bearing remover set, 25 mm 07936-ZV10100 Remover weight 07741-0010201...
  • Page 359 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Install the snap ring into the groove in the driven SNAP RING pulley face. • Check that the snap ring is seated in the groove. • Do not reuse the snap ring which could easily spin in the groove. Fill the inner face of the drive pulley face boss with 5.0 –...
  • Page 360 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH DRIVEN FACE SPRING INSPECTION Check the driven pulley face spring for fatigue or damage. Measure the driven pulley face spring free length. SERVICE LIMIT: 106.0 mm (4.17 in) DRIVEN FACE INSPECTION Check the driven pulley face for scratches, scoring or damage.
  • Page 361 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH ASSEMBLY • Apply specified quantity of grease to the inside of the driven pulley face and the guide grooves in the movable driven pulley face. • Avoid getting grease or oil on the clutch shoe lin- ings and driven pulley faces.
  • Page 362 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Install the movable driven pulley face onto the DRIVEN PULLEY FACE driven pulley face. Install the guide rollers and guide roller pins. Apply 4.0 – 5.0 g (0.14 – 0.18 oz) of grease to the driven face guide grooves of the movable driven pulley face.
  • Page 363 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Install the clutch side plate and secure it with the E- SIDE PLATE clips. E-CLIPS CLUTCH/DRIVEN PULLEY ASSEMBLY Assemble the following: DRIVEN PULLEY ASSEMBLY – Driven pulley assembly SPRING SEAT – Spring guide collar – Spring seat –...
  • Page 364 maxiscooter-club.ru DRIVE PULLEY/DRIVEN PULLEY/CLUTCH INSTALLATION Compress the driven pulley face spring by turning DRIVEN PULLEY FACE the movable driven face clockwise, and install the drive belt between the driven pulley faces. DRIVE BELT Install the clutch/driven pulley assembly onto the Be careful not to CLUTCH/DRIVEN PULLEY ASSEMBLY drive shaft, and the drive belt onto the drive pulley...
  • Page 365 TOOL: Flywheel holder 07725-0040001 TORQUE: 74 N·m (7.5 kgf·m, 55 lbf·ft) Install the drive pulley face. – NSS250S: (page 11-11) – NSS250A: (page 11-18) Install the left crankcase cover (page 11-9). FLYWHEEL HOLDER 11-37...
  • Page 366 maxiscooter-club.ru MEMO...
  • Page 367 maxiscooter-club.ru 12. FINAL REDUCTION COMPONENT LOCATION ························ 12-2 TROUBLESHOOTING······························· 12-5 SERVICE INFORMATION ························· 12-3 FINAL REDUCTION ·································· 12-6 12-1...
  • Page 368 maxiscooter-club.ru FINAL REDUCTION COMPONENT LOCATION FINAL REDUCTION NSS250A shown: 24 N·m (2.4 kgf·m, 18 lbf·ft) 12-2...

  • Page 369: Final Reduction

    After disassembly 0.30 liter (0.32 US qt, 0.26 Imp qt) Recommended final reduction oil Honda "4-stroke motorcycle oil" or an equivalent Oil recommendation: API classification: SG or higher (except oils labeled as energy conserving on the circular...
  • Page 370 maxiscooter-club.ru FINAL REDUCTION TOOLS Bearing remover shaft, 15 mm Bearing remover head, 15 mm Bearing remover, 20 mm 07936-KC10100 07936-KC10200 07936-3710600 Bearing remover handle Remover weight Pilot, 14 mm 07936-3710100 07741-0010201 07746-0041200 Pilot, 15 mm Pilot, 20 mm Pilot, 25 mm 07746-0040300 07746-0040500 07746-0040600...
  • Page 371 Engine starts but scooter won’t move • Damaged final reduction • Seized final reduction • Faulty drive pulley – NSS250S: (page 11-11) – NSS250A: (page 11-18) • Faulty clutch/driven pulley (page 11-27) Abnormal noise • Worn, seized or chipped gears •...
  • Page 372 maxiscooter-club.ru FINAL REDUCTION FINAL REDUCTION DISASSEMBLY Drain the final drive oil (page 4-17). COLLAR Remove the following: – Rear wheel (page 16-5) – Clutch/driven pulley (page 11-27) – VS sensor (page 22-20) Remove the rear wheel speed sensor (page 18-26). NSS250A: Remove the collar.
  • Page 373 maxiscooter-club.ru FINAL REDUCTION Remove the washer and counter gear. COUNTER GEAR WASHER Remove the final gear shaft. FINAL GEAR SHAFT Remove the counter gear shaft and washer. WASHER COUNTER GEAR SHAFT LEFT CRANKCASE BEARING Ball bearing BALL BEARING BALL BEARING Turn the inner race of the crankcase ball bearing with your finger.
  • Page 374 maxiscooter-club.ru FINAL REDUCTION FINAL REDUCTION CASE BEARING Ball bearing BALL BEARING BALL BEARING Turn the inner race of the final reduction case ball bearings with your finger. The ball bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the final reduction case.
  • Page 375 maxiscooter-club.ru FINAL REDUCTION BEARING REPLACEMENT Be careful not to damage the mating surfaces of the left crankcase and final reduction case. • Disassemble the final reduction case (page 12-6). NEEDLE BEARING FINAL GEAR SHAFT DUST SEAL COUNTER GEAR FINAL GEAR SHAFT BEARING (6205-2NSG) DRIVE SHAFT BEARING (6302) OIL SEAL...
  • Page 376 maxiscooter-club.ru FINAL REDUCTION Pack all bearing cavities with oil. FINAL GEAR SHAFT BEARING Drive in new bearings squarely with its marked side DRIVE SHAFT BEARING facing up until it is fully seated, using special tools. Final gear shaft bearing: TOOLS: Driver 07749-0010000 Attachment, 42 x 47 mm...
  • Page 377 maxiscooter-club.ru FINAL REDUCTION Pack all bearing cavities with oil. NEEDLE BEARING Drive new bearings into the final reduction case until it is fully seated using special tools. Final gear shaft bearing: TOOLS: Driver 07749-0010000 Attachment, 52 x 55 mm 07746-0010400 Pilot, 25 mm 07746-0040600 Drive shaft bearing:...
  • Page 378 maxiscooter-club.ru FINAL REDUCTION ASSEMBLY • Apply oil to each gear teeth and rolling area. Clean the mating surfaces of the final reduction case and left crankcase. MATING SURFACES Pull the drive shaft into the bearing inner race in the ASSEMBLY COLLAR left crankcase until it is fully seated, using special tools.
  • Page 379 maxiscooter-club.ru FINAL REDUCTION Apply oil to the final gear shaft teeth and journal. Install the final gear shaft. FINAL GEAR SHAFT Apply oil to the counter gear teeth and rolling area. Install the counter gear and washer. COUNTER GEAR WASHER Install the dowel pins to the left crankcase.
  • Page 380 maxiscooter-club.ru FINAL REDUCTION Install the final reduction case. FINAL REDUCTION CASE Install the bolts and tighten it to the specified torque BOLTS in a crisscross pattern in two or three steps. TORQUE: 24 N·m (2.4 kgf·m, 18 lbf·ft) Install the collar. COLLAR Install the rear wheel speed sensor (page 18-26).
  • Page 381 maxiscooter-club.ru 13. ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION ························ 13-2 RIGHT CRANKCASE COVER ··················· 13-4 SERVICE INFORMATION ························· 13-3 ALTERNATOR STATOR/CKP SENSOR··· 13-7 TROUBLESHOOTING ······························· 13-3 FLYWHEEL/STARTER CLUTCH ·············· 13-9 13-1...
  • Page 382 maxiscooter-club.ru ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION ALTERNATOR/STARTER CLUTCH 11 N·m (1.1 kgf·m, 8 lbf·ft) 103 N·m (10.5 kgf·m, 76 lbf·ft) 13-2...
  • Page 383 • This section covers the removal and installation of the flywheel, alternator/starter clutch and crankshaft position sensor. • These services can be done with the engine installed in the frame. • For alternator inspection (page 19-8) • For CKP sensor inspection: – NSS250S: (page 20-6) – NSS250A: (page 20-8) SPECIFICATIONS Unit: mm (in)
  • Page 384 maxiscooter-club.ru ALTERNATOR/STARTER CLUTCH RIGHT CRANKCASE COVER REMOVAL Drain the coolant (page 7-7). NSS250A shown: 2P (Red) CONNECTOR Drain the engine oil (page 4-11). Remove the following: – Right body cover (page 3-11) – Right floor skirt (page 3-9) – Muffler (page 3-32) Disconnect the following: –...
  • Page 385 maxiscooter-club.ru ALTERNATOR/STARTER CLUTCH Loosen the bolts in a crisscross pattern in two or three steps and remove the bolts and right crank- case cover. BOLTS RIGHT CRANKCASE COVER Remove the water joint collar and O-ring. DOWEL PINS OIL JOINT COLLAR/O-RING Remove the oil joint collar and O-ring.
  • Page 386 maxiscooter-club.ru ALTERNATOR/STARTER CLUTCH Install the right crankcase cover to the right crank- The alternator cover case by aligning the tab of the water pump shaft (stator) is with the groove of the oil pump driven sprocket magnetically bolt. attracted to the flywheel, be careful Align during installation.
  • Page 387 maxiscooter-club.ru ALTERNATOR/STARTER CLUTCH Install the parking brake cable clamp and rear brake BOLTS hose joint to the stay and install the bolts. Tighten the bolts securely. HOSE JOINT CABLE CLAMP Hook the alternator/CKP sensor wire to the clamp. NSS250A shown: 2P (Red) CONNECTOR Connect the following: –...
  • Page 388 maxiscooter-club.ru ALTERNATOR/STARTER CLUTCH INSTALLATION BOLT WIRE GROMMET STATOR BOLTS CKP SENSOR Install the stator and bolts. STATOR Tighten the bolts securely. BOLTS Route the alternator/CKP sensor wire and install the WIRE BAND wire band to the stay. WIRE 13-8...
  • Page 389 maxiscooter-club.ru ALTERNATOR/STARTER CLUTCH Apply sealant to the alternator wire grommet seat- CKP SENSOR GROMMET ing surface and install the grommet to the groove of the crankcase cover securely. Install the CKP sensor and bolts. Tighten the bolts securely. Install the right crankcase cover (page 13-5). BOLTS FLYWHEEL/STARTER CLUTCH REMOVAL...
  • Page 390 maxiscooter-club.ru ALTERNATOR/STARTER CLUTCH Remove the flywheel and starter driven gear as a FLYWHEEL PULLER set, using a special tool. TOOL: Flywheel puller 07933-KM10001 Remove the special tool. Remove the flywheel/starter driven gear assembly. FLYWHEEL/STARTER DRIVEN GEAR ASSEMBLY Remove the starter reduction gear and shaft. SHAFT STARTER REDUCTION GEAR Remove the woodruff key from the crankshaft.
  • Page 391 maxiscooter-club.ru ALTERNATOR/STARTER CLUTCH Hold the flywheel with a special tool and remove SOCKET BOLTS the starter clutch outer socket bolts. TOOL: Flywheel holder 07725-0040001 FLYWHEEL HOLDER Remove the sprag clutch/starter clutch outer from SPRAG CLUTCH SOCKET BOLTS the flywheel. FLYWHEEL INSPECTION Check the starter driven gear and reduction gear STARTER DRIVEN GEAR...
  • Page 392 maxiscooter-club.ru ALTERNATOR/STARTER CLUTCH ASSEMBLY STARTER DRIVEN GEAR CLUTCH OUTER SPRAG CLUTCH FLYWHEEL 23 N·m (2.3 kgf·m, 17 lbf·ft) Apply oil to the sprag clutch outer surface. CLUTCH OUTER SPRAG CLUTCH Install the sprag clutch by aligning the flange of the sprag clutch with the groove of the clutch outer.
  • Page 393 maxiscooter-club.ru ALTERNATOR/STARTER CLUTCH Clean the starter clutch outer socket bolt threads. SOCKET BOLTS Apply locking agent to the socket bolt threads (coat- ing width 4.5 ± 1.0 mm (0.18 ± 0.04 in) from the tip of exclude 2.0 – 3.0 mm (0.08 – 0.12 in)). Align the bolt holes on the starter clutch outer and flywheel.
  • Page 394 maxiscooter-club.ru ALTERNATOR/STARTER CLUTCH Degrease the taper of the flywheel. Install the flywheel to the crankshaft by aligning its groove with the woodruff key of the crankshaft. Align FLYWHEEL Apply oil to the flywheel bolt threads and seating BOLT/WASHER surface. Install the washer and flywheel bolt. Hold the flywheel with a special tool and tighten the flywheel bolt to the specified torque.
  • Page 395 maxiscooter-club.ru 14. CRANKCASE/CRANKSHAFT/BALANCER COMPONENT LOCATION ························ 14-2 MAIN JOURNAL BEARING ··················· 14-11 SERVICE INFORMATION ························· 14-3 CRANKPIN BEARING ····························· 14-16 TROUBLESHOOTING ······························· 14-4 BALANCER GEAR ·································· 14-18 CRANKCASE SEPARATION····················· 14-5 CRANKCASE ASSEMBLY ······················ 14-21 CRANKSHAFT··········································· 14-7 14-1...

  • Page 396: Component Location

    maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER COMPONENT LOCATION CRANKCASE/CRANKSHAFT/BALANCER 12 N·m (1.2 kgf·m, 9 lbf·ft) 33 N·m (3.4 kgf·m, 24 lbf·ft) 14-2...

  • Page 397: Service Information

    • The following parts must be removed before separating the crankcase. – Cylinder head (page 9-11) – Cylinder and piston (page 10-4) – Starter motor (page 21-6) – NSS250S: Drive pulley (page 11-11) – NSS250A: Drive pulley (page 11-18) – Clutch/driven pulley (page 11-27) – Flywheel/starter clutch (page 13-9) –...

  • Page 398: Troubleshooting

    maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER Driver Attachment, 42 x 47 mm Attachment, 62 x 68 mm 07749-0010000 07746-0010300 07746-0010500 Pilot, 15 mm Collar, 40 x 42.7 mm Driver base, 48.4 x 56 mm 07746-0040300 07965-VM00100 07946-KM90600 Metal installer 070MF-KTWR100 TROUBLESHOOTING Abnormal noise • Worn or damaged crankshaft main journal bearing •...

  • Page 399: Crankcase Separation

    maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER CRANKCASE SEPARATION Remove the engine from the frame (page 8-4). RIGHT SIDE: LEFT SIDE: Remove the parts required for crankcase separation (page 14-3). Remove the center stand springs. SPRINGS Remove the cotter pin, washer, center stand shaft LEFT SIDE: RIGHT SIDE: and center stand.
  • Page 400 maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER Place the left crankcase facing down and remove RIGHT CRANKCASE the right crankcase. LEFT CRANKCASE Remove the dowel pins. OIL JOINT COLLARS/ BALANCER GEAR Remove the oil joint collar and O-ring. O-RINGS Remove the water joint collar and O-ring. Remove the balancer gear (page 14-18).
  • Page 401 maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER Fill the bearing rolling area with oil. LEFT CRANKCASE: BALANCER GEAR Remove the bearings using special tools. BEARING TOOLS: Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 Pilot, 15 mm 07746-0040300 DRIVER ATTACHMENT/PILOT RIGHT CRANKCASE: DRIVER BALANCER GEAR BERING ATTACHMENT/PILOT CRANKSHAFT REMOVAL...
  • Page 402 maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER DISASSEMBLY/INSPECTION Check the timing sprockets for wear or damage. TIMING SPROCKETS Measure the connecting rod big end side clearance with a feeler gauge. SERVICE LIMIT: 0.40 mm (0.016 in) Loosen the bearing cap nuts alternately in two or Tap the side of the BEARING CAP CONNECTING ROD...
  • Page 403 maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER ASSEMBLY • For crankpin bearing replacement (page 14-16). Do not interchange the bearing inserts. They must be installed in their original locations or the correct bearing oil clearance may not be obtained, resulting in engine damage. Apply molybdenum oil solution to the crankpin CONNECTING ROD BEARING CAP bearing sliding surface.
  • Page 404 maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER INSTALLATION Install a new oil seal to the left crankcase using spe- OIL SEAL cial tools. TOOLS: Driver 07749-0010000 Attachment, 62 x 68 mm 07746-0010500 DRIVER ATTACHMENT Install the snap ring into the groove in the crank- SNAP RING OIL SEAL case.

  • Page 405: Main Journal Bearing

    maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER MAIN JOURNAL BEARING BEARING REMOVAL/INSPECTION Remove the crankshaft (page 14-7). Clean off any oil from the bearings. Check the bearings for abnormal wear, damage or peeling and replace them if necessary. MAIN JOURNAL BEARINGS MAIN JOURNAL OIL CLEARANCE Remove the crankshaft (page 14-7).
  • Page 406 maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER Press the main journal bearings toward the inside of BEARING the crankcase. COLLAR DRIVER BASE Measure and record the crankcase main journal I.D. Be careful not to INDEX MARK at between the main journal groove and crankcase damage the main outer side end, and 90°...
  • Page 407 maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER 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 color. O.D. CODE 14-13...
  • Page 408 maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER In case the crankshaft and crankcase are replaced: MAIN JOURNAL O.D. CODE NUMBER 39.994 – 40.000 mm 39.988 – 39.994 mm 39.982 – 39.988 mm (1.5746 – 1.5748 in) (1.5743 – 1.5746 in) (1.5741 – 1.5743 in) BEARING 45.000 –...
  • Page 409 maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER BEARING THICKNESS: O.S.E (Blue – Blue): Thick O.S.F (Black – Black): O.S.G (Brown – Brown): O.S.H (Green – Green): Middle A (Blue): B (Black): C (Brown): D (Green): Thin After selecting new bearings, recheck the clearance IDENTIFICATION COLOR with a plastigauge.

  • Page 410: Crankpin Bearing

    maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER Press the new bearings until the metal installer METAL INSTALLER flange fully seat. BEARINGS Make sure the bearing mating line aligns with the Aligned index mark on the crankcase. Check the oil clearance (page 14-11). • After selecting new bearings, recheck the oil clearance.
  • Page 411 maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER Apply oil to the bearing cap nut threads and seating BEARING CAP surface. Install the bearing cap and nuts. Do not rotate the Tighten the baring cap nuts alternately to the speci- crankshaft during fied torque in several steps. inspection.

  • Page 412: Balancer Gear

    maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER CRANKPIN BEARING SELECTION TABLE: CONNECTING ROD I.D. CODE 39.000 – 39.006 mm 39.006 – 39.012 mm 39.012 – 39.018 mm (1.5354 – 1.5357 in) (1.5357 – 1.5359 in) (1.5359 – 1.5361 in) CRANKPIN 35.994 – 36.000 mm O.D. CODE (1.4171 –...
  • Page 413 maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER Remove the balancer gear springs and sub-gear. SPRINGS SUB-GEAR Check the balancer shaft sub-gear and balancer SUB-GEAR gear for wear or damage. BALANCER GEAR Turn the inner race of the balancer gear bearing with your finger. The balancer gear bearing should turn smoothly and quietly.
  • Page 414 maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER ASSEMBLY BALANCER SPRINGS SUB-GEAR WASHER SNAP RING Apply molybdenum disulfide paste to the balancer SPRINGS shaft sub-gear sliding surface. Install the balancer shaft sub-gear and balancer gear springs. SUB-GEAR Install the washer and snap ring into the balancer WASHER gear shaft groove.

  • Page 415: Crankcase Assembly

    maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER INSTALLATION Align the balancer shaft sub-gear and balancer gear SUB-GEAR holes and install a pin into the holes. Install the balancer gear while aligning index marks of the sub-gear and crank gear. Assemble the crankcase halves (page 14-21). Align CRANK GEAR BALANCER GEAR...
  • Page 416 maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER Install the right crankcase on the left crankcase. RIGHT CRANKCASE LEFT CRANKCASE Install the bolts with wire harness stay. STAY Tighten the bolts in a crisscross pattern in two or three steps. BOLTS Apply oil to the following: BOLT CAM CHAIN TENSIONER –...
  • Page 417 maxiscooter-club.ru CRANKCASE/CRANKSHAFT/BALANCER Install the center stand springs. RIGHT SIDE: LEFT SIDE: Install the removed parts in the reverse order of removal. Install the engine to the frame (page 8-9). SPRINGS 14-23...
  • Page 418 maxiscooter-club.ru MEMO...
  • Page 419 maxiscooter-club.ru 15. FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION ························ 15-2 HANDLEBAR POST ································ 15-11 SERVICE INFORMATION ························· 15-3 FRONT WHEEL ······································· 15-13 TROUBLESHOOTING ······························· 15-5 FORK ······················································· 15-18 HANDLEBAR ············································· 15-6 STEERING STEM···································· 15-25 15-1...

  • Page 420: Component Location

    maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING COMPONENT LOCATION FRONT WHEEL/SUSPENSION/STEERING 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) 128 N·m (13.1 kgf·m, 94 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 69 N·m (7.0 kgf·m, 51 lbf·ft) 69 N·m (7.0 kgf·m, 51 lbf·ft) 22 N·m (2.2 kgf·m, 16 lbf·ft) 15-2...
  • Page 421 Fork Spring free length 325.3 (12.8) 315.5 (12.4) Tube runout – 0.2 (0.01) Honda Ultra Cushion Oil 10 W or Recommended fork fluid – equivalent Fluid level 90 (3.5) – 204 ± 2.5 cm (6.9 ± 0.08 US oz, 7.2 ±...
  • Page 422 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING TOOLS Pin spanner Bearing remover shaft Bearing remover head, 20 mm 07702-0020001 07GGD-0010100 07746-0050600 Attachment, 42 x 47 mm Attachment, 52 x 55 mm Inner driver, 35 mm 07746-0010300 07746-0010400 07746-0030400 Pilot, 20 mm Fork seal driver body Fork seal driver attachment, 35.2 mm 07746-0040500 07747-0010100...
  • Page 423 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Ball race remover shaft Remover weight 07JAC-PH80200 07741-0010201 TROUBLESHOOTING Hard steering • Insufficient tire pressure • Faulty tire • Steering stem adjusting nut too tight • Worn or damaged steering head bearing • Worn or damaged steering head bearing race •...
  • Page 424 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR REMOVAL Remove the left rearview mirror. NSS250A shown: LEFT REAR VIEW MIRROR • The left rearview mirror lock nut has left-hand WIRE BAND threads. Remove the wire band. Disconnect the inhibitor switch and rear brake light NSS250A shown: LEFT MASTER CYLINDER switch connectors.
  • Page 425 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Remove the right rearview mirror. WIRE BAND RIGHT REAR VIEW MIRROR • The right rearview mirror lock nut has left-hand threads. Remove the wire band. Remove the front brake light switch connectors. RIGHT MASTER CYLINDER HOLDER Remove the bolts, holder and right master cylinder. Keep the right master cylinder upright, to prevent...
  • Page 426 THROTTLE PIPE of the throttle pipe. Apply Honda Bond A or equivalent to the inside of the handlebar grip and to the clean surfaces of the left handlebar. Wait 3 – 5 minutes and install the grips.
  • Page 427 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Install the handlebar into the right handlebar switch SOCKET BOLTS HANDLEBAR housing/throttle grip. Install the handlebar onto the lower holders align- ing the punch mark on the handlebar with the top edge of the lower holder. Install the upper holders with the punch marks fac- ing forward.
  • Page 428 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Set the right master cylinder by aligning the end of RIGHT MASTER CYLINDER PUNCH MARK the master cylinder with the punch mark on the han- dlebar. HOLDER Set the holder with the "UP" mark facing up and tighten the upper bolt first, then tighten the lower bolt to the specified torque.

  • Page 429: Handlebar Post

    maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Install the screws and tighten the forward screw SCREWS first, then tighten the rear screw. LEFT HANDLE SWITCH HOUSING Set the left master cylinder by aligning the end of NSS250A shown: HOLDER PUNCH MARK the master cylinder with the punch mark on the han- dlebar.
  • Page 430 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Temporarily install the handlebar and remove the LOWER HOLDERS lower holder nuts. Remove the lower holders. HANDLEBAR NUTS Remove the bolts and handlebar post from the HANDLEBAR POST steering stem. Discard the bolts. BOLTS Remove the rubber seal. RUBBER SEAL Check the condition of the rubber seal, replace it if necessary.

  • Page 431: Front Wheel

    maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Install the handlebar post by aligning its pin with HANDLEBAR POST Align the cut-out of the steering stem. Install and tighten new handlebar post mounting bolts to the specified torque. TORQUE: 128 N·m (13.1 kgf·m, 94 lbf·ft) BOLTS Temporarily install the handlebar to the lower hold- LOWER HOLDERS...
  • Page 432 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Remove the left axle holder bolt. FRONT AXLE Remove the front axle and front wheel. Do not operate the brake lever after removing the front NSS250A: Be careful not to damage the front wheel wheel. speed sensor. AXLE HOLDER BOLT Remove the side collars.
  • Page 433 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING WHEEL BEARING Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not Replace the wheel turn smoothly, quietly, or if they fit loosely in the bearings in pairs.
  • Page 434 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Remove the dust seal. DUST SEAL Install the bearing remover head into the bearing. REMOVER SHAFT From opposite side of the wheel, install the bearing Replace the wheel remover shaft and drive the bearing out of the bearings in pairs.
  • Page 435 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Drive new left bearing (brake disc side) squarely ATTACHMENT/PILOT until it is fully seated, using special tools. DRIVER TOOLS: Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 Pilot, 20 mm 07746-0040500 Install the distance collar. Drive new right bearing squarely until it is fully seated, using special tools.

  • Page 436: Fork

    maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Install the front wheel between the fork legs while Be careful not to NSS250A shown: BOLT inserting the disc between the pads. damage the brake pads. NSS250A: Be careful not to damage the front wheel speed sensor. Apply grease to the front axle sliding surface.
  • Page 437 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Remove the upper fork mounting bolts. MOUNTING BOLTS (Remove) Loosen the lower fork mounting bolts and remove the fork pipes from the steering stem. MOUNTING BOLTS (Loosen) DISASSEMBLY Hold the bottom case in a vise with a soft jaws or Do not over-tighten shop towel.
  • Page 438 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Remove the dust seal. Be careful not to DUST SEAL STOPPER RING damage the fork Remove the stopper ring from the bottom case. pipe and bottom case. Remove the socket bolt and sealing washer. SOCKET BOLT SEALING WASHER Remove the fork piston and rebound spring from Do not remove the FORK PISTON...
  • Page 439 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Remove the oil lock piece from the bottom case. OIL LOCK PIECE Remove the back up ring and guide bushing from Do not remove the BACK UP RING the bottom case. fork pipe bushing unless it is necessary to replace it with a new one.
  • Page 440 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Place the fork pipe in V-blocks and measure the runout. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.2 mm (0.01 in) Visually inspect the fork pipe bushing and guide BUSHING BACK UP RING bushing. Replace the bushing if there is excessive scoring or scratching, or if the teflon is worn so that the copper surface appears on more than 3/4 of the entire sur-...
  • Page 441 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY FORK PIPE PISTON RING 22 N·m (2.2 kgf·m, 16 lbf·ft) FORK PIPE BUSHING OIL LOCK PIECE O-RING FORK PISTON BOTTOM CASE REBOUND SPRING FORK SPRING SEALING WASHER DUST SEAL FORK OIL SEAL STOPPER RING 29.4 N·m GUIDE BUSHING (3.0 kgf·m, 22 lbf·ft) BACK UP RING...
  • Page 442 Pour the specified amount of recommended fork fluid in the fork pipe. RECOMMENDED FORK FLUID: Honda Ultra Cushion Oil 10 W or equivalent FORK FLUID CAPACITY: 204 ± 2.5 cm (6.9 ± 0.08 US oz, 7.2 ± 0.09 Imp oz) 90 mm (3.5 in)

  • Page 443: Steering Stem

    maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Pull the fork pipe up fully. O-RING FORK CAP Install the fork spring with the tightly wound end BOLT facing down. Coat a new O-ring with fork fluid and install it into the groove in the fork cap bolt. Install the fork cap bolt and tighten it to the specified torque.
  • Page 444 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Hold the steering stem adjusting nut using the pin LOCK NUT SOCKET WRENCH spanner then loosen the steering stem lock nut using the socket wrench. TOOLS: Socket wrench 07916-KM10000 Pin spanner 07702-0020001 Remove the steering stem lock nut. ADJUSTING NUT PIN SPANNER Remove the lock washer.
  • Page 445 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Remove the steering stem and lower ball bearing. LOWER BALL BEARING STEERING STEM STEERING BEARING RACE REPLACEMENT Always replace the bearings and outer races as a REMOVER HEAD set. Remove the upper outer race using special tools. TOOLS: Ball race remover 07YAC-0010102...
  • Page 446 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Drive a new upper bearing outer race into the head DRIVER pipe using special tools. TOOLS: Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 ATTACHMENT UPPER OUTER RACE LOWER INNER RACE REPLACEMENT Remove the lower bearing inner race with a chisel LOWER INNER RACE DUST SEAL or equivalent tool being careful not to damage the...
  • Page 447 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING INSTALLATION EXTREME PRESSURE GREASE: LOCK NUT · BEARING · BEARING RACE LOCK WASHER · DUST SEAL STEERING STEM ADJUSTING NUT STEERING STEM UPPER DUST SEAL UPPER INNER RACE UPPER BALL BEARING UPPER OUTER RACE LOWER OUTER RACE LOWER BEARING LOWER INNER RACE LOWER DUST SEAL...
  • Page 448 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Install and tighten the steering stem adjusting nut to Refer to torque STEERING STEM ADJUSTING NUT the specified torque. wrench reading information on page TOOL: 15-3 ‘‘Service Pin spanner 07702-0020001 Information‘‘. TORQUE: Actual: 25 N·m (2.5 kgf·m, 18 lbf·ft) Indicated: 18 N·m (1.8 kgf·m, 13 lbf·ft) PIN SPANNER Turn the steering stem lock-to-lock several times to...
  • Page 449 maxiscooter-club.ru FRONT WHEEL/SUSPENSION/STEERING Install the lock nut. LOCK NUT WRENCH Hold the steering stem adjusting nut using the pin spanner then tighten the steering stem lock nut using the socket wrench to the specified torque. TOOLS: Socket wrench 07916-KM10000 Pin spanner 07702-0020001 TORQUE: 74 N·m (7.5 kgf·m, 55 lbf·ft) Support the scooter securely and raise the front...
  • Page 450 maxiscooter-club.ru MEMO...
  • Page 451 maxiscooter-club.ru 16. REAR WHEEL/PARKING BRAKE/SUSPENSION COMPONENT LOCATION ························ 16-2 REAR WHEEL/SWINGARM ····················· 16-5 SERVICE INFORMATION ························· 16-3 PARKING BRAKE LEVER ······················· 16-15 TROUBLESHOOTING ······························· 16-4 REAR SHOCK ABSORBER ····················· 16-16 16-1...
  • Page 452 maxiscooter-club.ru REAR WHEEL/PARKING BRAKE/SUSPENSION COMPONENT LOCATION REAR WHEEL/PARKING BRAKE/SUSPENSION 39 N·m (4.0 kgf·m, 29 lbf·ft) 11 N·m (1.1 kgf·m, 8 lbf·ft) 49 N·m (5.0 kgf·m, 36 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 118 N·m (12.0 kgf·m, 87 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 16-2...
  • Page 453 • Use only tires marked “TUBELESS” and tubeless valve stems on rims marked "TUBELESS TIRE APPLICATION". • Use genuine Honda replacement bolts and nuts for all suspension pivot and mounting point. • NSS250A: After installing the rear wheel, measure the clearance (air gap) between the sensor and pulser ring (page 18- 26).
  • Page 454 maxiscooter-club.ru REAR WHEEL/PARKING BRAKE/SUSPENSION TROUBLESHOOTING Rear wheel wobbles • Bent rim • Faulty tire • Unbalanced tire and wheel • Axle nut and/or engine mounting bolt not tightened properly • Loose or worn final gear shaft bearing • Insufficient tire pressure Soft suspension •...
  • Page 455 maxiscooter-club.ru REAR WHEEL/PARKING BRAKE/SUSPENSION REAR WHEEL/SWINGARM REMOVAL Remove the muffler (page 3-32). REAR AXLE NUT Support the scooter securely on its center stand. Apply parking brake and loosen the rear axle nut, then unlock the parking brake. Remove the mounting bolts and rear brake caliper Do not operate the REAR BRAKE CALIPER from the swingarm.
  • Page 456 maxiscooter-club.ru REAR WHEEL/PARKING BRAKE/SUSPENSION Remove the right shock absorber lower mounting MOUNTING BOLT bolt. Remove the rear axle nut. SWINGARM MOUNTING BOLTS Remove the mounting bolts and swingarm. AXLE NUT SWINGARM Remove the parking brake drum. PARKING BRAKE DRUM Remove the rear wheel. REAR WHEEL 16-6...
  • Page 457 maxiscooter-club.ru REAR WHEEL/PARKING BRAKE/SUSPENSION INSPECTION WHEEL Check the wheel rim runout using dial indicators. Actual runout is 1/2 the total indicator readings. SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in) WHEEL BALANCE For wheel balance inspection (page 15-14). PARKING BRAKE Measure the parking brake drum I.D.
  • Page 458 maxiscooter-club.ru REAR WHEEL/PARKING BRAKE/SUSPENSION PARKING BRAKE DISASSEMBLY/ INSPECTION Remove the side collar. SIDE COLLAR Mark the brake shoes to ensure that they are rein- Replace the brake SHOE SPRINGS BRAKE SHOES stalled on their original location. shoes as a set. Remove the brake shoes and springs by spreading the brake shoes.
  • Page 459 maxiscooter-club.ru REAR WHEEL/PARKING BRAKE/SUSPENSION Check the dust seal for deterioration or damage and replace it if necessary. DUST SEAL Remove the bolts, muffler bracket and shock MUFFLER BRACKET absorber bracket. BOLTS SHOCK ABSORBER BRACKET Remove the dust seals from the swingarm. DUST SEAL BEARING Turn the inner race of the bearing with your finger.
  • Page 460 maxiscooter-club.ru REAR WHEEL/PARKING BRAKE/SUSPENSION Drive in a new bearing into the swingarm squarely The marked side of DRIVER ATTACHMENT/ until it is fully seated, using special tools. the bearing is PILOT facing to the special TOOLS: tools. Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 Pilot, 17mm 07746-0040400...
  • Page 461 maxiscooter-club.ru REAR WHEEL/PARKING BRAKE/SUSPENSION PARKING BRAKE ASSEMBLY BRAKE ARM 10 N·m (1.0 kgf·m, 7 lbf·ft) RETURN SPRING COLLAR MUFFLER BRACKET BRAKE CAM SNAP RING DUST SEAL 30 N·m (3.1 kgf·m, 22 lbf·ft) BEARING SHOCK ABSORBER BRACKET SHOE SPRINGS BRAKE SHOES Install the shock absorber bracket and muffler MUFFLER BRACKET bracket and tighten the bolts to the specified torque.
  • Page 462 maxiscooter-club.ru REAR WHEEL/PARKING BRAKE/SUSPENSION Install the return spring by installing its end into the RETURN SPRING hole on the swingarm. Align Hook the return spring hook to the parking brake BRAKE ARM BOLT arm and install the parking brake arm to the brake cam by aligning the punch marks.
  • Page 463 maxiscooter-club.ru REAR WHEEL/PARKING BRAKE/SUSPENSION WHEEL ASSEMBLY Install the brake disc onto the wheel hub with the SOCKET BOLTS STAMP stamp facing out. Install new socket bolts and tighten them to the specified torque. TORQUE: 42 N·m (4.3 kgf·m, 31 lbf·ft) Install the rear pulser ring (page 18-28).
  • Page 464 maxiscooter-club.ru REAR WHEEL/PARKING BRAKE/SUSPENSION Install the joint pin, brake cable, and adjusting nut to ADJUSTING NUT CLAMP BOLT the brake arm. Set the parking brake cable clamp to the swingarm and tighten the bolt. JOINT PIN PARKING BRAKE CABLE Install and tighten the air cleaner housing mounting AIR CLEANER HOUSING bolt/washers to the specified torque.

  • Page 465: Parking Brake Lever

    maxiscooter-club.ru REAR WHEEL/PARKING BRAKE/SUSPENSION PARKING BRAKE LEVER REMOVAL/INSTALLATION PARKING BRAKE LEVER LINK Remove the inner cover (page 3-27). BOLT Remove the bolt and inner cover guard from the parking brake lever link. Disconnect the parking brake switch connectors. CONNECTORS INNER COVER GUARD Loosen the lock nut and disconnect the parking BOLTS PARKING BRAKE CABLE...

  • Page 466: Rear Shock Absorber

    maxiscooter-club.ru REAR WHEEL/PARKING BRAKE/SUSPENSION REAR SHOCK ABSORBER REMOVAL Support the scooter securely on its center stand. SHOCK ABSORBER Jack up the scooter to relieve stress from the shock absorber. Remove the shock absorber mounting bolts and shock absorber. BOLTS INSPECTION Check the dumper unit for leakage or other damage.
  • Page 467 maxiscooter-club.ru 17. HYDRAULIC BRAKE COMPONENT LOCATION ························ 17-2 RIGHT MASTER CYLINDER ··················· 17-17 SERVICE INFORMATION ························· 17-4 LEFT MASTER CYLINDER ····················· 17-22 TROUBLESHOOTING ······························· 17-6 DELAY VALVE ········································ 17-27 BRAKE FLUID REPLACEMENT/ FRONT BRAKE CALIPER························ 17-28 AIR BLEEDING ·········································· 17-7 REAR BRAKE CALIPER ··························...

  • Page 468: Component Location

    maxiscooter-club.ru HYDRAULIC BRAKE COMPONENT LOCATION HYDRAULIC BRAKE FRONT NSS250A shown: NSS250A: 12 N·m (1.2 kgf·m, 9 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 17-2...
  • Page 469 maxiscooter-club.ru HYDRAULIC BRAKE REAR NSS250A shown: NSS250A: 12 N·m (1.2 kgf·m, 9 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 34 N·m (3.5 kgf·m, 25 lbf·ft) 30 N·m (3.1 kgf·m, 22 lbf·ft) 17-3...

  • Page 470: Service Information

    maxiscooter-club.ru HYDRAULIC BRAKE SERVICE INFORMATION GENERAL Frequent inhalation of brake pad 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 and OSHA-approved vacuum cleaner. Spilled brake fluid will severely damage instrument lenses and painted surfaces.
  • Page 471 maxiscooter-club.ru HYDRAULIC BRAKE TORQUE VALUES Caliper bleed valve 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft) Brake caliper mounting bolt 30 N·m (3.1 kgf·m, 22 lbf·ft) ALOC bolt; replace with a new one. Rearview mirror adaptor bolt 26 N·m (2.7 kgf·m, 19 lbf·ft) Rearview mirror lock nut 26 N·m (2.7 kgf·m, 19 lbf·ft) Left-hand threads...

  • Page 472: Troubleshooting

    maxiscooter-club.ru HYDRAULIC BRAKE TROUBLESHOOTING Brake lever soft or spongy • Air in hydraulic system • Leaking hydraulic system • Low brake fluid level • Clogged fluid passage • Warped/deformed brake disc • Contaminated brake pad/disc • Worn brake pad/disc • Badly worn brake pad/disc •...

  • Page 473: Brake Fluid Replacement

    maxiscooter-club.ru HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING Spilled fluid can damage painted, plastic, or rubber parts. Place a rag over these parts whenever the system is serviced. Never allow contaminates (dirt, water, etc.) to get into an open reservoir. BRAKE FLUID DRAINING RIGHT BRAKE LINE Support the scooter on its center stand and turn the SCREWS...
  • Page 474 maxiscooter-club.ru HYDRAULIC BRAKE LEFT (COMBINED) BRAKE LINE Remove the muffler (page 3-32). SCREWS RESERVOIR CAP Support 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 left master cylinder.
  • Page 475 • Be sure that each parts is free from the dust or dirt before reassembly. • Use only DOT 4 brake fluid from a sealed con- tainer. • Do not mix different types of fluid. There are not compatible. NSS250S: RIGHT MASTER CYLINDER LEFT MASTER CYLINDER DELAY VALVE REAR BRAKE CALIPER...
  • Page 476 maxiscooter-club.ru HYDRAULIC BRAKE RIGHT BRAKE LINE Connect a commercially available brake bleeder to the upper bleed valve of the front caliper. • Follow the manufacturer's operating instruc- tions. Loosen the front brake caliper upper bleed valve If an automatic refill NSS250A shown: and perform the bleeging procedure until the sys- system is not used,...
  • Page 477 maxiscooter-club.ru HYDRAULIC BRAKE Connect a bleed hose to the upper bleed valve and FRONT UPPER bleed the system as follows: BLEED VALVE 1. Pump the right brake lever several (5 – 10) times, then squeeze the right brake lever all the way and loosen the bleed valve 1/4 of a turn.
  • Page 478 maxiscooter-club.ru HYDRAULIC BRAKE Loosen the front brake caliper lower bleed valve, Check the fluid BLEED VALVE perform the bleeding procedure until the system is level often while REAR BRAKE LEVER completely flushed/bled. bleeding the brakes to prevent air from Tighten the front brake caliper lower bleed valve to being pumped into the specified torque.

  • Page 479: Air Bleeding

    maxiscooter-club.ru HYDRAULIC BRAKE Connect a bleed hose to the front brake caliper NSS250A shown: lower bleed valve. BLEED VALVE Repeat step for rear caliper bleed valve. Next perform the air bleeding from the system (page 17-13). AIR BLEEDING: Connect a bleed hose to the rear caliper bleed valve and bleed the system as follows: 1.

  • Page 480: Brake Pad/Disc

    maxiscooter-club.ru HYDRAULIC BRAKE BRAKE PAD/DISC BRAKE PAD REPLACEMENT Check the brake operation by applying the brake lever after replacing the brake pads. FRONT Push the caliper pistons all the way in by pushing Check the fluid NSS250A shown: the caliper body inward to allow installation of new level in the master brake pads.
  • Page 481 maxiscooter-club.ru HYDRAULIC BRAKE Apply silicone grease to a new pad pin stopper ring NSS250A shown: STOPPER RING outer surface. Install the pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper.
  • Page 482 maxiscooter-club.ru HYDRAULIC BRAKE Hold the rear caliper pin and remove the rear caliper Do not reuse the CALIPER BOLT CALIPER PIN bolt. rear caliper bolt. • Be careful not to damage the caliper pin boot. BOOT Remove the brake pads. BRAKE PADS Clean the inside of the caliper especially around the caliper piston.

  • Page 483: Right Master Cylinder

    maxiscooter-club.ru HYDRAULIC BRAKE BRAKE DISC INSPECTION Visually inspect the brake disc for damage or crack. NSS250A shown: Measure the brake disc thickness with a microme- ter. SERVICE LIMITS: FRONT: 4.0 mm (0.16 in) REAR: 5.0 mm (0.20 in) Replace the brake disc if the smallest measurement is less than the service limit.
  • Page 484 maxiscooter-club.ru HYDRAULIC BRAKE Remove the brake hose oil bolt, sealing washers OIL BOLT SEALING WASHERS and brake hose eyelet. BRAKE HOSE Remove the master cylinder holder bolts, holder MASTER CYLINDER and master cylinder. HOLDER BOLTS DISASSEMBLY Remove the pivot nut, pivot bolt and brake lever. PIVOT BOLT BRAKE LEVER PIVOT NUT...
  • Page 485 maxiscooter-club.ru HYDRAULIC BRAKE Remove the piston boot from the master cylinder SNAP RING/WASHER and master piston. Remove the snap ring using a special tool. TOOL: Snap ring pliers 07914-SA50001 Remove the washer, master piston and spring. Clean the master cylinder, reservoir and master pis- Be sure that each ton in clean brake fluid.
  • Page 486 maxiscooter-club.ru HYDRAULIC BRAKE • Keep the piston, cups, spring, snap ring and boot as a set; do not replace the parts individually. • Be sure that each parts is free from the dust or dirt before reassembly. Coat the master piston outer surface, piston cup SPRING whole surface and master cylinder inner surface with clean DOT 4 brake fluid.
  • Page 487 maxiscooter-club.ru HYDRAULIC BRAKE Fill the contact surfaces with 0.10 g (0.004 oz) mini- PIVOT BOLT mum of silicone grease of the brake lever, piston tip and brake lever pivot bolt sliding surface. BRAKE LEVER Install the brake lever. Install the pivot bolt and tighten it to the specified torque.

  • Page 488: Left Master Cylinder

    maxiscooter-club.ru HYDRAULIC BRAKE LEFT 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, cover the end of the hose to prevent contamination. Secure the hose to prevent fluid from leaking out.
  • Page 489 maxiscooter-club.ru HYDRAULIC BRAKE DISASSEMBLY Remove the pivot nut, pivot bolt and brake lever. PIVOT BOLT BRAKE LEVER PIVOT NUT Remove the screws and brake light/inhibitor switch. SCREWS BRAKE LIGHT/INHIBITOR SWITCH Remove the piston boot from the master cylinder SNAP RING PLIERS and master piston.
  • Page 490 maxiscooter-club.ru HYDRAULIC BRAKE ASSEMBLY NSS250A shown: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) BOOT MASTER PISTON DIAPHRAGM PLATE SPRING SNAP RING DIAPHRAGM MASTER PISTON CUPS CYLINDER 1.0 N·m (0.1 kgf·m, 0.7 lbf·ft) BRAKE LIGHT/ INHIBITOR SWITCH BRAKE LEVER 6 N·m (0.6 kgf·m, 4.4 lbf·ft) 1.2 N·m (0.1 kgf·m, 0.9 lbf·ft) •...
  • Page 491 maxiscooter-club.ru HYDRAULIC BRAKE Install the snap ring into the groove in the master Install the snap ring SNAP RING cylinder. with its chamfered edge facing the TOOL: thrust load side. Snap ring pliers 07914-SA50001 • Check that the snap ring is seated in the groove. •...
  • Page 492 maxiscooter-club.ru HYDRAULIC BRAKE INSTALLATION Install the master cylinder and holder with the "UP" NSS250A shown: PUNCH MARK MASTER mark facing up. CYLINDER Align the end of the master cylinder with the punch HOLDER mark on the handlebar and tighten the upper bolt first then tighten the lower bolt.

  • Page 493: Delay Valve

    maxiscooter-club.ru HYDRAULIC BRAKE DELAY VALVE REMOVAL/INSTALLATION 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, cover the end of the hose or pipe to prevent contamination. Secure the hose to prevent fluid from leaking out.

  • Page 494: Front Brake Caliper

    maxiscooter-club.ru HYDRAULIC BRAKE FRONT BRAKE CALIPER REMOVE 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, cover the end of the hose to prevent contamination. Secure the hose to prevent fluid from leaking out.
  • Page 495 maxiscooter-club.ru HYDRAULIC BRAKE Place a shop towel over the pistons. Position the caliper body with the pistons down and apply short bursts of air pressure to the fluid inlet to remove the three pistons. • Do not use high pressure air or bring the nozzle too close to the inlet.
  • Page 496 maxiscooter-club.ru HYDRAULIC BRAKE ASSEMBLY CALIPER BRACKET CALIPER PIN BOOT BRAKE PADS RETAINER 12 N·m (1.2 kgf·m, 9 lbf·ft) 5.4 N·m (0.6 kgf·m, 4.0 lbf·ft) CALIPER PISTONS DUST SEALS 17 N·m (1.7 kgf·m, 13 lbf·ft) PISTON SEALS PAD SPRING STOPPER RING BRACKET PIN BOOT •...
  • Page 497 maxiscooter-club.ru HYDRAULIC BRAKE Install the retainer onto the caliper bracket. CALIPER BODY RETAINER BRACKET Check the caliper/bracket pin boots and replace them if they are hard, deteriorated or damage. Install the pad spring onto the caliper body as Note the installation shown.

  • Page 498: Rear Brake Caliper

    maxiscooter-club.ru HYDRAULIC BRAKE REAR BRAKE CALIPER 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, cover the end of the hose to prevent contamination. Secure the hose to prevent fluid from leaking out.
  • Page 499 maxiscooter-club.ru HYDRAULIC BRAKE Push the dust seal and piston seal in and lift them Be careful not to PISTON SEAL out. damage the piston sliding surface. Clean the seal grooves, caliper cylinder and piston with clean brake fluid. DUST SEAL INSPECTION Check the caliper cylinder for scoring, scratches or CALIPER BODY...
  • Page 500 maxiscooter-club.ru HYDRAULIC BRAKE • Be sure that each parts is free from the dust or dirt before reassembly. Coat a new dust seal with silicone grease. Coat a new piston seal with clean brake fluid. Install the piston seal and dust seal into the seal DUST SEAL grooves in the caliper cylinder.
  • Page 501 maxiscooter-club.ru 18. ABS (NSS250A) ABS SYSTEM LOCATION ························ 18-2 ABS INDICATOR CIRCUIT TROUBLESHOOTING····························· 18-12 ABS SYSTEM DIAGRAM ························· 18-3 ABS TROUBLESHOOTING ···················· 18-15 SERVICE INFORMATION ························· 18-4 FRONT WHEEL SPEED SENSOR ·········· 18-24 ABS CONNECTOR LOCATIONS ·············· 18-5 FRONT PULSER RING···························· 18-25 ABS TROUBLESHOOTING INFORMATION ·········································...

  • Page 502: Abs System Location

    maxiscooter-club.ru ABS (NSS250A) ABS SYSTEM LOCATION ABS (NSS250A) RIGHT MASTER CYLINDER LEFT MASTER CYLINDER ABS MODULATOR REAR WHEEL SPEED SENSOR DELAY VALVE REAR BRAKE CALIPER REAR PULSER RING FRONT BRAKE CALIPER FRONT WHEEL SPEED SENSOR FRONT PULSER RING 18-2...

  • Page 503: Abs System Diagram

    maxiscooter-club.ru ABS (NSS250A) ABS SYSTEM DIAGRAM FUSE/RELAY BOX ABS MODULATOR ABS (81) ABS MOTOR FUSE ABS (54) 8 FAIL SAFE RLY 30 A R/Bl PUMP MOTOR ABS FSR ABS (51,52,53) FUSE Bl/G 9 + MOTOR MOTOR GND 25 30 A BATTERY MAIN B SC-S 13...

  • Page 504: Service Information

    maxiscooter-club.ru ABS (NSS250A) SERVICE INFORMATION GENERAL The ABS modulator may be damaged if dropped. Also, if the connector is disconnected when current is flowing, the exces- sive voltage may damage the control unit. Always turn the ignition switch OFF before servicing. •...

  • Page 505: Abs Connector Locations

    maxiscooter-club.ru ABS (NSS250A) ABS CONNECTOR LOCATIONS NOTE 1: Remove the front side cover (page 3-21). ABS MODULATOR 25P CONNECTOR FRONT WHEEL SPEED SENSOR 2P (Blue) CONNECTOR 18-5...
  • Page 506 maxiscooter-club.ru ABS (NSS250A) NOTE 2: Remove the luggage lower box (page 3-16). REAR WHEEL SPEED SENSOR 2P (Orange) CONNECTOR NOTE 3: Remove the battery cover (page 19-6). ABS SERVICE CHECK 3P (Natural) CONNECTOR 18-6...
  • Page 507 maxiscooter-club.ru ABS (NSS250A) ABS TROUBLESHOOTING INFORMATION SYSTEM DESCRIPTION SUMMARY OF ABS PRE-START SELF-DIAGNOSIS SYSTEM The ABS pre-start self-diagnosis system diagnoses the electrical system as well as the operating status of the modulator. When there is any abnormality, the problem and the problematic part can be detected by outputting the problem code.
  • Page 508 maxiscooter-club.ru ABS (NSS250A) PROBLEM CODE INDICATION PATTERN • The ABS indicator indicates the problem code by blinking a specified number of times. The indicator has two types of blinkings, a long blink and short blink. The long blink lasts for 1.3 sec- onds, the short blink lasts for 0.3 seconds.
  • Page 509 maxiscooter-club.ru ABS (NSS250A) 2. Turn the ignition switch ON and engine stop ABS INDICATOR switch " ". The ABS indicator starts problem code indica- tion. 3. Note how many times the ABS indicator blinks, and determine the cause of the problem (page 18-10).
  • Page 510 maxiscooter-club.ru ABS (NSS250A) ABS INDICATOR PROBLEM CODE INDEX • The ABS indicator might blink in the following cases. Correct the faulty part. – Incorrect tire pressure. – Tires not recommended for the scooter were installed (incorrect tire size). – Deformation of the wheel or tire. •...
  • Page 511 maxiscooter-club.ru ABS (NSS250A) Detection Problem Refer Function failure Symptom/Fail-safe function Code Fail-safe relay malfunction • Fail-safe relay (ABS modulator) or related • Stops ABS operation 18-21 wires • ABS FSR fuse (30 A) Power circuit/Under voltage • Input voltage (too low) •...

  • Page 512: Abs Indicator Circuit

    maxiscooter-club.ru ABS (NSS250A) ABS INDICATOR CIRCUIT TROUBLESHOOTING ABS INDICATOR DOES NOT COME ON (when the ignition switch turned ON) 1. Combination Meter Power/ground Line Inspection Check the combination meter power and ground lines (page 22-10). Are the wires normal? – GO TO STEP 2. –...
  • Page 513 maxiscooter-club.ru ABS (NSS250A) ABS INDICATOR STAYS ON (Indicator does not go off when the scooter is running and problem code is not indicated by the retrieval procedure) 1. Service Check Line Short Circuit Inspection Turn the ignition switch OFF. 25P CONNECTOR Disconnect the ABS modulator 25P connector (Wire side/female terminals) (page 18-28).
  • Page 514 maxiscooter-club.ru ABS (NSS250A) 3. Indicator Operation Inspection Connect the combination meter 28P (Gray) con- 28P CONNECTOR nector (page 22-10). Turn the ignition switch ON, engine stop switch to " ". With the combination meter 28P connector con- nected, short the Red/black wire terminal of the combination meter and ground with a jumper wire.

  • Page 515: Abs Troubleshooting

    maxiscooter-club.ru ABS (NSS250A) ABS TROUBLESHOOTING • Perform inspection with the ignition switch turned OFF, unless otherwise specified. • Refer to the ABS connector locations (page 18-5). All connector diagrams in the troubleshooting are viewed from the terminal side. • Use a fully charged battery. Do not diagnose with a charger connected to the battery.
  • Page 516 maxiscooter-club.ru ABS (NSS250A) 2. Front Wheel Speed Sensor Condition Inspection Inspect the area around the front wheel speed WHEEL SPEED SENSOR sensor: Check that there is iron or other magnetic depos- its between the pulser ring and front wheel speed sensor, and the pulser ring slots for obstructions.
  • Page 517 maxiscooter-club.ru ABS (NSS250A) 5. Front Wheel Speed Sensor Line Open Circuit Inspection Disconnect the ABS modulator 25P connector 25P CONNECTOR (page 18-28). (Wire side/female terminals) Short the Pink/black and Green/orange wire ter- minals of the ABS modulator 25P connector with a jumper wire.
  • Page 518 maxiscooter-club.ru ABS (NSS250A) PROBLEM CODE 13, 14, 23 or 43 (Rear Wheel Speed Sensor/Rear Pulser Ring/Rear Wheel Lock) • The ABS indicator might blink under unusual riding or conditions (page 18-10). This is intermit- tent failure. Erase the problem code (page 18-9) then test ride the scooter above 30 km/h (18 mph) and check the problem code by retrieving the self-diagnosis system (page 18-8).
  • Page 519 maxiscooter-club.ru ABS (NSS250A) 4. Rear Wheel Speed Sensor Line Short Circuit Inspection Turn the ignition switch OFF. SPEED SENSOR 2P (Orange) CONNECTOR Check for continuity between each terminal (Wire side/female terminals) (Pink/white and Green/red) of the wire side of the rear wheel speed sensor 2P connector and ground.
  • Page 520 maxiscooter-club.ru ABS (NSS250A) PROBLEM CODE 31, 32, 33, 34, 37 or 38 (Solenoid Valve) 1. Failure Reproduction Erase the problem code (page 18-9). ABS INDICATOR Test ride the scooter above 30 km/h (18 mph). Retrieve the problem code (page 18-8) and recheck the ABS indicator.
  • Page 521 maxiscooter-club.ru ABS (NSS250A) 3. Failure Reproduction Connect the ABS modulator 25P connector. ABS INDICATOR Erase the problem code (page 18-9). Test ride the scooter above 30 km/h (18 mph). Retrieve the problem code (page 18-8). Does the indicator blink 51, 52, or 53 times? –...
  • Page 522 maxiscooter-club.ru ABS (NSS250A) 2. Relay Power Input Line Short Circuit Inspection Check the continuity between the ABS modula- 25P CONNECTOR tor 25P connector of the wire side and ground. (Wire side/female terminals) TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: Red/green – Ground Is there continuity? –...
  • Page 523 maxiscooter-club.ru ABS (NSS250A) 2. ABS Power Input Line Open Circuit Inspection Turn the ignition switch OFF. 25P CONNECTOR Check the continuity between the ABS modula- (Wire side/female terminal) tor of the wire side and ground. TOOL: Test probe 07ZAJ-RDJA110 CONNECTION: Black/light green (+) – Green (–) Does the battery voltage exist? Black/light green –...

  • Page 524: Front Wheel Speed Sensor

    maxiscooter-club.ru ABS (NSS250A) PROBLEM CODE 81 (ABS Control Unit) 1. Failure Reproduction Erase the problem code (page 18-9). ABS INDICATOR Test ride the scooter above 30 km/h (18 mph). Retrieve the problem code (page 18-8). Does the indicator blink 81 times? –...

  • Page 525: Front Pulser Ring

    maxiscooter-club.ru ABS (NSS250A) Remove the bolts and wire clamps. BOLT BOLT CLAMP Remove the bolts and front wheel speed sensor. CLAMP BOLTS WHEEL SPEED SENSOR Check that there is iron or other magnetic deposits between the pulser ring and wheel speed sensor. Remove any deposits.

  • Page 526: Rear Wheel Speed Sensor

    maxiscooter-club.ru ABS (NSS250A) REAR WHEEL SPEED SENSOR INSPECTION Support the scooter on its center stand and raise the 0.2 – 1.2 mm (0.01 – 0.05 in) rear wheel off the ground. Measure the clearance (air gap) between the sensor and pulser ring at several points by turning the wheel slowly.
  • Page 527 maxiscooter-club.ru ABS (NSS250A) Remove the bolts and rear wheel speed sensor. BOLTS Check the rear wheel speed sensor for scratch or damage, replace it if necessary. Install the rear wheel speed sensor and bolts. Tighten the rear wheel speed sensor bolts. REAR WHEEL SPEED SENSOR Install the VS sensor protector and new socket bolts.

  • Page 528: Rear Pulser Ring

    maxiscooter-club.ru ABS (NSS250A) REAR PULSER RING INSPECTION Support the scooter on its center stand and raise the PULSER RING rear wheel off the ground. Check the pulser ring for scratch or damage. Replace the pulser ring if necessary. REMOVAL/INSTALLATION Remove the rear wheel (page 16-5). PULSER RING Remove the torx bolts and pulser ring.
  • Page 529 maxiscooter-club.ru ABS (NSS250A) Loosen the joint nuts and disconnect the brake Be careful not to BRAKE PIPES pipes. bend or damage the brake pipes. JOINT NUTS BRAKE PIPES Remove the bolts and brake pipe joints. BOLT BOLT BRAKE PIPE JOINT BRAKE PIPE JOINTS Remove the bolt and brake pipe joint.
  • Page 530 maxiscooter-club.ru ABS (NSS250A) Remove the bolt/washers. Remove the ABS modulator from the frame. Be careful not to bend or damage the brake pipes during ABS modulator assembly removal. BOLT/WASHERS MODULATOR INSTALLATION ABS MODULATOR BRAKE PIPE (TO FRONT BRAKE CALIPER) BOLT/WASHER BRAKE PIPE (TO DELAY VALVE) BRAKE PIPE (TO RIGHT MASTER CYLINDER) BRAKE PIPE (TO REAR...
  • Page 531 maxiscooter-club.ru ABS (NSS250A) Install the bolt/washer. BOLT/WASHER Apply brake fluid to the joint nut threads. Be careful not to BOLT JOINT NUT bend or damage Connect the brake pipe and joint nut. the brake pipes. Tighten the joint nut to the specified torque. TORQUE: 14 N·m (1.4 kgf·m, 10 lbf·ft) Connect the brake pipe joint and install and tighten the bolt.
  • Page 532 maxiscooter-club.ru ABS (NSS250A) Connect the ABS modulator 25P connector by push- 25P CONNECTOR (LOCK LEVER) 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). 18-32...
  • Page 533 maxiscooter-club.ru 19. BATTERY/CHARGING SYSTEM SYSTEM LOCATION································· 19-2 BATTERY ·················································· 19-6 SYSTEM DIAGRAM·································· 19-2 CHARGING SYSTEM INSPECTION········· 19-7 SERVICE INFORMATION ························· 19-3 ALTERNATOR CHARGING COIL ············· 19-8 TROUBLESHOOTING ······························· 19-4 REGULATOR/RECTIFIER ························· 19-9 19-1...

  • Page 534: System Location

    BATTERY/CHARGING SYSTEM SYSTEM LOCATION BATTERY/CHARGING SYSTEM NSS250A shown: REGULATOR/RECTIFIER NSS250S: BATTERY FUSE/RELAY BOX: – MAIN FUSE (40 A) ALTERNATOR SYSTEM DIAGRAM MAIN A FUSE 40A : Green : Red REGULATOR/RECTIFIER : White BATTERY : Yellow ALTERNATOR 19-2...
  • Page 535 maxiscooter-club.ru BATTERY/CHARGING SYSTEM SERVICE INFORMATION GENERAL • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. • The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield.
  • Page 536 maxiscooter-club.ru BATTERY/CHARGING SYSTEM TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK 1. BATTERY TEST Remove the battery (page 19-6). Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER: BM-210 or BATTERY MATE or equivalent Is the battery in good condition? –...
  • Page 537 maxiscooter-club.ru BATTERY/CHARGING SYSTEM 7. REGULATOR/RECTIFIER SYSTEM INSPECTION Check the voltage and resistance at the regulator/rectifier connector (page 19-9). Are the results of checked voltage and resistance correct? – Faulty regulator/rectifier. – • Open circuit in related wire. • Loose or poor contacts of related terminal. •...
  • Page 538 maxiscooter-club.ru BATTERY/CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Turn the ignition switch OFF. Always turn the NSS250A shown: SCREWS Open the front seat and luggage box mat. ignition switch OFF BATTERY COVER before removing Remove the screws and battery cover. the battery. Remove the screws and battery band. NSS250A shown: BATTERY BAND SCREWS...

  • Page 539: Charging System Inspection

    maxiscooter-club.ru BATTERY/CHARGING SYSTEM VOLTAGE INSPECTION Remove the battery cover (page 19-6). Measure the battery voltage using a digital multimeter. VOLTAGE: Fully charged: 13.0 – 13.2 V Under charged: Below 12.4 V If the battery voltage is below 12.4 V, charge the bat- tery (page 19-7).

  • Page 540: Alternator Charging Coil

    maxiscooter-club.ru BATTERY/CHARGING SYSTEM CHARGING VOLTAGE INSPECTION Be sure the battery is in good condition before per- (–) PROBE forming this test. Warm up the engine to normal operating tempera- ture. Stop the engine and remove the battery band (page 19-6). •...

  • Page 541: Regulator/Rectifier

    maxiscooter-club.ru BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER SYSTEM INSPECTION Remove the right body cover (page 3-11). NSS250A shown: Disconnect the regulator/rectifier 2P (Black) and alternator 3P (Black) connectors, and check it for loose contact or corroded terminals. 2P CONNECTOR If the charging voltage reading (page 19-8) is out of NSS250A shown: the specification, then measure the voltage between the regulator/rectifier connector terminals of the...
  • Page 542 maxiscooter-club.ru MEMO...
  • Page 543 maxiscooter-club.ru 20. IGNITION SYSTEM SYSTEM LOCATION································· 20-2 IGNITION SYSTEM INSPECTION············ 20-5 SYSTEM DIAGRAM·································· 20-2 IGNITION COIL ······································· 20-10 SERVICE INFORMATION ························· 20-3 IGNITION TIMING ·································· 20-11 TROUBLESHOOTING ······························· 20-4 20-1...

  • Page 544: System Location

    IGNITION SYSTEM SYSTEM LOCATION IGNITION SYSTEM NSS250A shown: ENGINE STOP SWITCH BANK ANGLE SENSOR NSS250S: IGNITION SWITCH BATTERY IGNITION COIL FUSE/RELAY BOX: – ECU, IGN FUSE (10 A) – MAIN B FUSE (15 A) – ENGINE STOP RELAY CKP SENSOR...
  • Page 545 TP sensor and ECT sensor. • Following components information. – Ignition switch (page 23-26) – NSS250S: Engine stop switch (page 22-27) – NSS250A: Engine stop switch (page 22-29) – Sidestand switch (page 22-33) –...
  • Page 546 maxiscooter-club.ru IGNITION SYSTEM TROUBLESHOOTING • Inspect the following before diagnosing the system. – Faulty spark plug – Loose spark plug cap or spark plug wire connection – Water got into the spark plug cap (leaking the ignition coil secondary voltage) •...

  • Page 547: Ignition System Inspection

    maxiscooter-club.ru IGNITION SYSTEM IGNITION SYSTEM INSPECTION • If there is no spark present at the plug, check all connections for loose or poor contact before measuring the peak voltage. • Use a commercially available digital multimeter (impedance 10 MΩ/DCV minimum). •...
  • Page 548 – Spark plug cap (page 4-7) – Right floor step (page 3-12) – Left floor side panel (page 3-6) CKP SENSOR PEAK VOLTAGE (NSS250S) USING THE TEST PROBE • Check all system connections before performing this inspection. If the system is disconnected, incorrect peak voltage might be measured.
  • Page 549 maxiscooter-club.ru IGNITION SYSTEM If the peak voltage measured at the ECM connector is normal, measure the peak voltage at the CKP sen- sor connector. Turn the ignition switch OFF. Disconnect the CKP sensor 2P (Red) connector. Connect the peak voltage adapter to the CKP sensor 2P connector terminals of the sensor side.
  • Page 550 maxiscooter-club.ru IGNITION SYSTEM If the peak voltage measured at the test harness is normal, measure the peak voltage at the CKP sensor connector. Turn the ignition switch OFF. Disconnect the CKP sensor 2P (Red) connector. Connect the peak voltage adapter to the CKP sensor 2P connector terminals of the sensor side.
  • Page 551 maxiscooter-club.ru IGNITION SYSTEM If the peak voltage measured at the PCM connector is normal, measure the peak voltage at the CKP sen- sor connector. Turn the ignition switch OFF. Disconnect the CKP sensor 2P (Red) connector. Connect the peak voltage adapter to the CKP sensor 2P connector terminals of the sensor side.

  • Page 552: Ignition Coil

    maxiscooter-club.ru IGNITION SYSTEM If the peak voltage measured at the test harness is normal, measure the peak voltage at the CKP sensor connector. Turn the ignition switch OFF. Disconnect the CKP sensor 2P (Red) connector. Connect the peak voltage adapter to the CKP sensor 2P connector terminals of the sensor side.

  • Page 553: Ignition Timing

    maxiscooter-club.ru IGNITION SYSTEM IGNITION TIMING Start the engine, warm it up to normal operating temperature and stop it. Remove the timing hole cap. TIMING HOLE CAP Remove the maintenance lid of the luggage lower TIMING LIGHT box (page 3-16). • Read the instructions for timing light operation. Connect the timing light to the spark plug wire.
  • Page 554 maxiscooter-club.ru MEMO...
  • Page 555 maxiscooter-club.ru 21. ELECTRIC STARTER SYSTEM LOCATION································· 21-2 TROUBLESHOOTING······························· 21-4 SYSTEM DIAGRAM·································· 21-2 STARTER MOTOR ···································· 21-6 SERVICE INFORMATION ························· 21-3 STARTER RELAY SWITCH····················· 21-15 21-1...
  • Page 556 STARTER RELAY SWITCH SYSTEM DIAGRAM INHIBITOR SWITCH STARTER RELAY SWITCH STARTER SWITCH Bl Bl/Bu BATTERY R/Bl STARTER MOTOR NSS250S: Bl/R NSS250A: Bl IGNITION SWITCH : Black : Blue R/Bl MAIN B FUSE : Green ENGINE STOP 15 A SIDESTAND : Red...

  • Page 557: Service Information

    – Ignition switch (page 23-26) – NSS250S: Starter switch (page 22-27) – NSS250A: Starter switch (page 22-29) – Starter inhibitor switch (page 22-31) – NSS250S: Engine stop switch (page 22-27) – NSS250A: Engine stop switch (page 22-29) – Sidestand switch (page 22-33) SPECIFICATION...

  • Page 558: Troubleshooting

    maxiscooter-club.ru ELECTRIC STARTER TROUBLESHOOTING Starter motor does not turn 1. Fuse Inspection Check for blown MAIN B fuse (15 A) or ECU, IGN fuse (10 A). Is the fuse blown? – Replace the fuse. – GO TO STEP 2. 2. Battery Inspection Make sure the battery is fully charged and in good condition.
  • Page 559 Is there battery voltage? – GO TO STEP 7. – • Faulty ignition switch (page 23-26) • Faulty engine stop switch – NSS250S: (page 22-27) – NSS250A: (page 22-29) • Faulty inhibitor switch (page 22-31) • Faulty starter switch – NSS250S: (page 22-27) –...

  • Page 560: Starter Motor

    maxiscooter-club.ru ELECTRIC STARTER STARTER MOTOR REMOVAL • With the ignition switch OFF, disconnect the bat- tery negative (–) cable before servicing the starter motor. Remove the left side rear cover (page 4-15). GROUND CABLES MOTOR CABLE Uncover the terminal cover and remove the nut and starter motor cable from the starter motor.
  • Page 561 maxiscooter-club.ru ELECTRIC STARTER Remove the front cover and seal ring. SEAL RING FRONT COVER Remove the rear cover and seal ring. REAR COVER SEAL RING Remove the motor case from the armature. ARMATURE MOTOR CASE Remove the brushes from the brush holder. BRUSH HOLDER BRUSHES 21-7...
  • Page 562 maxiscooter-club.ru ELECTRIC STARTER Remove the springs from the brush holder. BRUSH HOLDER SPRINGS Check for continuity between the starter motor Continuity: CABLE TERMINAL cable terminal and positive brushes. (+) BRUSHES There should be continuity. Check for continuity between the positive brushes No continuity: REAR COVER (terminal bolt side) and rear cover.
  • Page 563 maxiscooter-club.ru ELECTRIC STARTER Remove the terminal nut. Remove the following: O-RING – Washer – Insulator INSULATOR – Terminal stopper – O-ring WASHER TERMINAL STOPPER Remove the terminal bolt, positive brushes and (+) BRUSHES brush holder from the rear cover. BRUSH HOLDER TERMINAL BOLT Inspect the brushes for damage and measure the brush length.
  • Page 564 maxiscooter-club.ru ELECTRIC STARTER Check the commutator for damage or abnormal ARMATURE wear. Check the commutator bar for discoloration. Do not use emery Clean the metallic debris off between commutator or sand paper on bars. the commutator. Replace the armature with a new one if necessary. COMMUTATOR Check for continuity between pairs of commutator Continuity:...
  • Page 565 maxiscooter-club.ru ELECTRIC STARTER Check the bushing of the rear cover for wear or BUSHING damage. ASSEMBLY 4.9 N·m (0.5 kgf·m, 3.6 lbf·ft) O-RING FRONT COVER SEAL RING TERMINAL BOLT MOTOR CASE SEAL RING ARMATURE (+) BRUSHES (–) BRUSHES INSULATOR WASHER SPRING BRUSH HOLDER REAR COVER...
  • Page 566 maxiscooter-club.ru ELECTRIC STARTER Install the following: O-RING – New O-ring – Terminal stopper INSULATOR – Insulator – Washer WASHER TERMINAL STOPPER Install and tighten the terminal nut. Install the negative brushes and screw. (–) BRUSHES Tighten the screw securely. SCREW Install the springs to the brush holder.
  • Page 567 maxiscooter-club.ru ELECTRIC STARTER Install the brushes to the brush holder. BRUSH HOLDER BRUSHES Install the armature to the motor case. ARMATURE MOTOR CASE Install a new seal ring to the motor case. Install the motor case aligning its groove with the Be careful not to tab on the rear cover.
  • Page 568 maxiscooter-club.ru ELECTRIC STARTER Align the index marks on the front cover, motor case and rear cover. Align Install the bolts and tighten them to the specified torque. TORQUE: 4.9 N·m (0.5 kgf·m, 3.6 lbf·ft) BOLTS INSTALLATION Apply oil to a new O-ring and install it to the groove of the front cover.
  • Page 569 maxiscooter-club.ru ELECTRIC STARTER STARTER RELAY SWITCH OPERATION INSPECTION Remove the battery band (page 19-6). STARTER RELAY SWITCH Retract the sidestand and support the scooter on its center stand. Turn the ignition switch ON and engine stop switch " ". Squeeze the left brake lever fully and push the starter switch.
  • Page 570 maxiscooter-club.ru ELECTRIC STARTER CONTINUITY INSPECTION Remove the starter relay switch (page 21-16). Connect a fully charged 12 V battery positive (+) ter- minal to the relay switch Yellow/red wire terminal and negative (–) terminal to the Green/white wire terminal. Connect an ohmmeter to the starter relay switch large terminals.
  • Page 571 SYSTEM LOCATION································· 22-2 EOP SWITCH ·········································· 22-25 SERVICE INFORMATION ························· 22-3 FUEL GAUGE/FUEL LEVEL SENSOR ··· 22-26 TROUBLESHOOTING ······························· 22-5 HANDLEBAR SWITCHES (NSS250S) ··· 22-27 HEADLIGHT··············································· 22-7 HANDLEBAR SWITCHES (NSS250A) ··· 22-29 FRONT TURN SIGNAL LIGHT/POSITION BRAKE LIGHT SWITCH ·························· 22-31 LIGHT·························································...

  • Page 572: System Location

    LIGHTS/METERS/SWITCHES SYSTEM LOCATION LIGHTS/METERS/SWITCHES NSS250A shown: TURN SIGNAL RELAY LUGGAGE BOX LIGHT SWITCH NSS250S: FUEL PUMP/UNIT PARKING BRAKE SWITCH HORN VS SENSOR FUSE/RELAY BOX: – HEADLIGHT RELAY (Lo) – HEADLIGHT RELAY (Hi) – MAIN RELAY EOP SWITCH SIDESTAND SWITCH...

  • Page 573: Service Information

    LED x 6 Turn signal indicator LED x 2 High beam indicator Parking brake indicator Oil pressure indicator Honda smart card key indicator ABS warning indicator (NSS250A) S mode indicator (NSS250A) D mode indicator (NSS250A) A/M mode indicator (NSS250A) Fuse...
  • Page 574 maxiscooter-club.ru LIGHTS/METERS/SWITCHES TORQUE VALUES Combination meter screw 1.1 N·m (0.1 kgf·m, 0.8 lbf·ft) Sidestand switch bolt 10 N·m (1.0 kgf·m, 7 lbf·ft) ALOC bolt; replace with a new one VS sensor protector socket bolt 10 N·m (1.0 kgf·m, 7 lbf·ft) ALOC bolt;...

  • Page 575: Troubleshooting

    maxiscooter-club.ru LIGHTS/METERS/SWITCHES TROUBLESHOOTING VS SENSOR/COMBINATION METER The speedometer operate normally, but the odometer/trip meter does not operate normally 1. Fuse Inspection Check for blown HORN, WINKER METER (ILLMI) fuse (15 A). Is the fuse blown? – Replace the fuse. – GO TO STEP 2. 2.
  • Page 576 maxiscooter-club.ru LIGHTS/METERS/SWITCHES 4. VS Sensor Signal Line Short Circuit Inspection Check for continuity between the combination meter 28P connector of the wire side and ground. CONNECTION: Pink/green – Ground Is there continuity? – Short circuit in Pink/green wire – Faulty VS sensor 22-6...

  • Page 577: Headlight

    maxiscooter-club.ru LIGHTS/METERS/SWITCHES HEADLIGHT • For headlight removal/installation (page 3-22) BULB REPLACEMENT Remove the console box (page 3-24). Left side headlight: MAINTENANCE LID Remove the right inner box (page 3-26). Right side headlight: Remove the trim clip and headlight maintenance lid. TRIM CLIP Disconnect the headlight connector.

  • Page 578: Front Turn Signal Light/Position

    maxiscooter-club.ru LIGHTS/METERS/SWITCHES FRONT TURN SIGNAL LIGHT/ POSITION LIGHT • For front turn signal light and position light removal/installation (page 3-22) BULB REPLACEMENT FRONT TURN SIGNAL LIGHT Remove the front lower cover (page 3-20). SOCKET Remove the turn signal light bulb socket by turning it counterclockwise.

  • Page 579: License Light

    maxiscooter-club.ru LIGHTS/METERS/SWITCHES REAR TURN SIGNAL LIGHT Remove the rear body lower cover (page 3-10). BULB Remove the rear turn signal light bulb socket by turning it counterclockwise. Remove the bulb from the socket. Installation is in the reverse order of removal. SOCKET LICENSE LIGHT •...

  • Page 580: Combination Meter

    maxiscooter-club.ru LIGHTS/METERS/SWITCHES COMBINATION METER SYSTEM INSPECTION Remove the screen garnish (page 3-18). 28P CONNECTOR Disconnect the combination meter 28P (Gray) con- nector. Perform the following inspection at combination meter connector of the wire side. POWER VOLTAGE INPUT LINE Turn the ignition switch ON then measure the volt- 28P CONNECTOR age between the combination meter connector of (Wire side/female terminal)
  • Page 581 If there is no continuity, check for an open circuit in Green/black wire. Green/black CURRENT FUEL CONSUMPTION METER INSPECTION (NSS250S) • The current fuel consumption meter has the fuel INSTANT FUEL CONSUMPTION consumption of the average and instant. • The current fuel consumption meter displays the...
  • Page 582 maxiscooter-club.ru LIGHTS/METERS/SWITCHES Average fuel consumption indicator shows [ _ _ . _ ] (under score: EEPROM failure) with test probe 1. Reset The TRIP A Display the "TRIP A" by pressing the MODE but- MODE BUTTON ton. Push and hold the RESET switch for 2 second. When the meter is reset properly, [ –...
  • Page 583 maxiscooter-club.ru LIGHTS/METERS/SWITCHES 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- MODE BUTTON ton. Push and hold the RESET switch 2 for second. When the meter is reset properly, [ –...
  • Page 584 maxiscooter-club.ru LIGHTS/METERS/SWITCHES CURRENT FUEL CONSUMPTION METER INSPECTION (NSS250A) • The current fuel consumption meter has the fuel INSTANT FUEL CONSUMPTION consumption of the average and instant. • The current fuel consumption meter displays the calculated average fuel consumption by receiv- ing the pulse signals of the PCM from the point ERROR: where the meter is reset.
  • Page 585 maxiscooter-club.ru LIGHTS/METERS/SWITCHES 3. Injection Pulse Line Open Circuit Inspection Turn the ignition switch OFF. 28P CONNECTOR Remove the screen garnish (page 3-18). (Wire side/female terminal) Disconnect the PCM 33P (Black) connector (page 6-102). Disconnect the combination meter 28P (Gray) connector (page 22-10). Brown/white Brown/white Check the continuity between the PCM 33P and...
  • Page 586 maxiscooter-club.ru LIGHTS/METERS/SWITCHES 3. Injection Pulse Line Open Circuit Inspection Turn the ignition switch OFF. 28P CONNECTOR Remove the screen garnish (page 3-18). (Wire side/female terminal) Connect the test harness 33P to the PCM 33P (Black) connector (page 6-102). TOOL: ECM test harness 33P 070MZ-MCA0100 Disconnect the combination meter 28P (Gray) (26)
  • Page 587 maxiscooter-club.ru LIGHTS/METERS/SWITCHES DISASSEMBLY/ASSEMBLY Remove the screws and meter lens. METER LENS SCREWS Remove the screws and inner case, printed circuit LOWER CASE SCREWS board from the lower case. INNER CASE/PRINTED CIRCUIT BOARD ASSEMBLY Assemble is in the reverse order of disassembly. SCREWS PRINTED CIRCUIT BOARD INNER CASE...

  • Page 588: Speedometer/Vs Sensor

    maxiscooter-club.ru LIGHTS/METERS/SWITCHES INSTALLATION Install the combination meter and screws and COMBINATION METER SCREWS tighten them to the specified torque. TORQUE: 1.1 N·m (0.1 kgf·m, 0.8 lbf·ft) Install the rear meter panel (page 3-22). SPEEDOMETER/VS SENSOR SYSTEM INSPECTION When the ignition switch turns ON, check that all NSS250A shown: gauge needles move to full scale and then return to zero.
  • Page 589 LIGHTS/METERS/SWITCHES VS SENSOR INSPECTION (NSS250S) Remove the left side rear cover (page 4-15). VS SENSOR 3P CONNECTOR Check for loose or poor contact of the VS sensor 3P (Black) connector. Turn the ignition switch OFF. Disconnect the VS sensor 3P (Black) connector.
  • Page 590 maxiscooter-club.ru LIGHTS/METERS/SWITCHES VS SENSOR INSPECTION (NSS250A) WITH TEST HARNESS Remove the left side rear cover (page 4-15). VS SENSOR 3P CONNECTOR Check for loose or poor contact of the VS sensor 3P (Black) connector. Disconnect the VS sensor 3P (Black) connector. Turn the ignition switch ON, engine stop switch "...

  • Page 591: Tachometer

    TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) O-RING TACHOMETER SYSTEM INSPECTION (NSS250S) When the ignition switch turns ON, check all gauge needles move to full scale and then return to zero. If the tachometer needle does not show initial func- tion but other needles show initial functions, faulty combination meter.
  • Page 592 maxiscooter-club.ru LIGHTS/METERS/SWITCHES TACHOMETER SIGNAL LINE OPEN CIRCUIT INSPECTION WITH TEST PROBE Disconnect the following: 28P CONNECTOR – Combination meter 28P (Gray) connector (page (Wire side/female terminal) 22-10) – ECM 33P (Black) connector (page 6-98) Check the continuity between the combination Blue/yellow Blue/ meter and ECM 33P connectors of the wire side.
  • Page 593 maxiscooter-club.ru LIGHTS/METERS/SWITCHES If the tachometer needle shows initial function, but 28P CONNECTOR tachometer does not move with the engine 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.

  • Page 594: Coolant Temperature Gauge

    maxiscooter-club.ru LIGHTS/METERS/SWITCHES COOLANT TEMPERATURE GAUGE/ ECT SENSOR SYSTEM INSPECTION When the ignition switch turns ON, check all gauge COOLANT TEMPERATURE GAUGE needles move to full scale and then return to zero. If the coolant temperature gauge needle does not show initial function but other needles show initial functions, faulty combination meter.

  • Page 595: Eop Switch

    maxiscooter-club.ru LIGHTS/METERS/SWITCHES NEEDLE MOVES BUT IT MOVES ABNORMAL Remove the ECT sensor (page 6-92). ECT SENSOR Suspend the ECT sensor in a pan of coolant (1:1 Keep all flammable mixture) on an electric heating element and mea- materials away sure the resistance between the ECT sensor termi- from the electric nal and body as the coolant heats up.

  • Page 596: Fuel Gauge/Fuel Level Sensor

    maxiscooter-club.ru LIGHTS/METERS/SWITCHES FUEL GAUGE/FUEL LEVEL SENSOR FUEL GAUGE INSPECTION When the ignition switch turns ON, check that all FUEL LEVEL GAUGE gauge needles move to full scale and then return to zero. If the fuel gauge needle does not show initial func- tion but other needles show initial functions, faulty combination meter.

  • Page 597: Handlebar Switches (Nss250S)

    LIGHTS/METERS/SWITCHES HANDLEBAR SWITCHES (NSS250S) INSPECTION Remove the front side cover (page 3-21). LEFT HANDLEBAR SWITCH 12P CONNECTOR Disconnect the right handlebar switch 8P (Green) and left handlebar switch 12P (Blue) connectors. RIGHT HANDLEBAR SWITCH 8P CONNECTOR RIGHT HANDLEBAR SWITCHES...
  • Page 598 maxiscooter-club.ru LIGHTS/METERS/SWITCHES LEFT HANDLEBAR SWITCHES Check for continuity between the connector termi- PASSING SWITCH DIMMER SWITCH nals in each switch position. Continuity should exist between the color code wires as shown in the charts. Turn Signal Switch: 12P (Blue) connector TURN SIGNAL SWITCH PUSH COLOR...

  • Page 599: Handlebar Switches (Nss250A)

    maxiscooter-club.ru LIGHTS/METERS/SWITCHES HANDLEBAR SWITCHES (NSS250A) INSPECTION Remove the front side cover (page 3-21). LEFT HANDLEBAR: RIGHT HANDLEBAR: Disconnect the following: 12P CONNECTOR 8P CONNECTOR – Right handlebar switch 8P (Green) connector – Left handlebar switch 12P (Blue) connector – Shift switch 3P (Black) connector –...
  • Page 600 maxiscooter-club.ru LIGHTS/METERS/SWITCHES LEFT HANDLEBAR SWITCHES Check for continuity between the connector termi- PASSING SWITCH SHIFT SWITCH nals in each switch position. Continuity should exist between the color code wires as shown in the charts. Turn Signal Switch: 12P (Blue) connector TURN SIGNAL SWITCH PUSH DIMMER SWITCH...

  • Page 601: Brake Light Switch

    maxiscooter-club.ru LIGHTS/METERS/SWITCHES BRAKE LIGHT SWITCH RIGHT BRAKE LIGHT SWITCH Disconnect the brake light switch connectors and NSS250A shown: check the continuity between the switch side termi- nals. There should be continuity with the right brake lever squeezed, and there should be no continuity when the right brake lever is released.

  • Page 602: Parking Brake Light Switch

    maxiscooter-club.ru LIGHTS/METERS/SWITCHES PARKING BRAKE LIGHT SWITCH INSPECTION Remove the inner cover (page 3-27). SCREW Disconnect the parking brake light switch connec- tors and check the continuity between the switch side terminals. There should be continuity with the parking brake lever pulled, and there should be no continuity when the parking brake lever is released.

  • Page 603: Sidestand Switch

    maxiscooter-club.ru LIGHTS/METERS/SWITCHES Remove the nuts and seat lock stay. SEAT LOCK STAY Installation is in the reverse order of removal. NUTS SIDESTAND SWITCH INSPECTION Remove the left floor step (page 3-12). Disconnect the sidestand switch 2P (Gray) connec- tor. 2P CONNECTOR Check the continuity between the wire terminals of the sidestand switch connector.

  • Page 604: Horn

    maxiscooter-club.ru LIGHTS/METERS/SWITCHES INSTALLATION Install the sidestand switch by aligning the boss of SIDESTAND SWITCH the sidestand switch with the hole of the sidestand. Align Install and tighten a new sidestand switch bolt to BOLT the specified torque. TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) Connect the sidestand switch 2P (Black) connector.

  • Page 605: Turn Signal Relay

    maxiscooter-club.ru LIGHTS/METERS/SWITCHES TURN SIGNAL RELAY INSPECTION 1. Recommended Inspection Check the following: – Battery condition (page 19-7) – Burned out bulb or non-specified wattage – Burned HORN, WINKER METER (ILLUMI) fuse (15 A) – Ignition switch function (page 23-26) – Turn signal/hazard relay operation (page 22- –...
  • Page 606 maxiscooter-club.ru LIGHTS/METERS/SWITCHES Connect the ohmmeter to the relay terminals. RELAY CONNECTION: A – B Connect the 12 V battery to the following relay ter- minals. CONNECTION: C – D 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 relay.
  • Page 607 CONSOLE BOX LOCK RELEASE DIAGNOSTIC CODE INDICATION ··········· 23-8 ACTUATOR ············································· 23-32 TROUBLESHOOTING ····························· 23-10 SEAT LOCK RELEASE ACTUATOR ······· 23-34 TEST HARNESS CONNECTION············· 23-17 ANSWER BACK RELAY ························· 23-36 Honda Smart Card Key INDICATOR ····· 23-18 ANSWER BACK DIODE ·························· 23-36 23-1...

  • Page 608: System Location

    Honda Smart Card Key System SYSTEM LOCATION Honda Smart Card Key System NSS250A shown: Honda Smart Card Key Honda Smart Card Key system ON/OFF SWITCH LF ANTENNA SEAT/CONSOLE BOX LOCK RELEASE BUTTON CONSOLE BOX LOCK RELEASE ACTUATOR Honda Smart Card Key...

  • Page 609: Service Information

    • The Honda Smart Card Key has built-in electronic part. Do not drop or strike the card key against a hard object, and do not leave the card key on the dashboard in the car, etc. where the temperature will rise. Do not leave the card key in the water for a prolonged time such as by washing the clothes.

  • Page 610: System Diagram

    Honda Smart Card Key System SYSTEM DIAGRAM ENGINE STOP ENGINE STOP MAIN B FUSE SWITCH RELAY IGNITION SWITCH ECU,IGN FUSE 10A 15 A Bl/O R/Bl R/Bl Bl/W SMART KEY FUSE 10 A BATTERY CLOCK,TRUNK, ANSWER BACK FUSE 10 A...
  • Page 611 • Check that the ignition switch is OFF and locked. • Be sure to re-register any registered card key except the originally registered card key. • The operating range of the Honda Smart Card Key is about 80 cm (31.5 in) from the handle lock mod- ule.
  • Page 612 9. Turn the ignition switch OFF, disconnect the inspection adaptor and connect the dummy connector to the registration connector. • The Honda Smart Card Key System returns to the normal mode. 10.Check if the ignition switch can be turned ON using all the newly registered card keys.
  • Page 613 EM connector. • When the short connector is connected to the EM connector, it becomes impossible to start the Honda Smart Card Key System by registered card key. 4. Push the ignition switch. • When the ID number input mode starts success- fully, ignition switch light (Blue LED) starts to stay on.

  • Page 614: Procedure

    Turn the ignition switch ON with the properly regis- Honda Smart Card Key INDICATOR tered card key. The Honda Smart Card Key indicator will come on for approx. ten seconds then it will start blinking to indicate the diagnostic code if the system is abnor- mal.
  • Page 615 Honda Smart Card Key System When the system (Handle lock module) enters the diagnostic mode from the registration mode: BLINKING PATTERN SYMPTOM PROBLEM PROCEDURE Code key sig- Faulty LF Follow the trouble- nals cannot be antenna or wire shooting (page 23-...

  • Page 616: Troubleshooting

    Honda Smart Card Key System TROUBLESHOOTING The Honda Smart Card Key indicator comes on for approx. two seconds then it goes off, when the igni- tion switch is turned ON with the properly registered card key and the Honda Smart Card Key System functions normally.
  • Page 617 Honda Smart Card Key System The ignition switch can be turned ON and engine starts but Honda Smart Card Key indicator stays on 1. Honda Smart Card Key Indicator Line Inspection Turn the ignition switch OFF and check the continuity between the handle lock module 21P connec- tor of the wire side and ground.
  • Page 618 Honda Smart Card Key System Diagnostic code is indicated (Code signals cannot be received) 1. Card Key Battery Inspection Replace the card key battery with a new one and check if the diagnostic code indicates. Does the diagnostic code indicate? –...
  • Page 619 Check if the ignition switch light (Blue LED) starts blinking thirty seconds after the ignition switch is pushed. Does the ignition switch blinks? – • NSS250S: Inspect the EM connector line (page 23-25). • NSS250A: Inspect the EM connector line (page 23-25). – Faulty handle lock module 5.
  • Page 620 Does MIL stay on for two seconds? – See "ENGINE DOES NOT START OR IS HARD TO START" (page 26-2). – • Goes off – NSS250S: Inspect the PGM-FI system (page 6-95). – NSS250A: Inspect the PGM-FI system (page 6-99). • Stay on –...
  • Page 621 5. Handle Lock Module Communication Line Open Circuit Inspection Turn the ignition switch OFF. Disconnect the following: – NSS250S: ECM 33P (Black) connector (page 6-95) – NSS250A: PCM 21P (Black) 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.
  • Page 622 Honda Smart Card Key System Seat/Console Box Does Not Open 1. Mechanical Key Inspection Check if the seat and console box can be opened using the mechanical key. Can the seat and console box be opened? – GO TO STEP 2.

  • Page 623: Test Harness Connection

    Honda Smart Card Key System TEST HARNESS CONNECTION Remove the inner cover (page 3-27). Connect the RF unit 5P (Green) connector (page 23- 28). Turn the ignition switch OFF. Disconnect the handle lock module 21P (Black) con- nector. HANDLE LOCK MODULE...

  • Page 624: Honda Smart Card Key Indicator

    Honda Smart Card Key System Honda Smart Card Key INDICATOR Remove the screen garnish (page 3-18). COMBINATION METER 28P CONNECTOR Perform the following inspection with the combina- tion meter 28P (Gray) connector connected. INPUT VOLTAGE LINE INSPECTION Measure the voltage at the combination meter 28P COMBINATION METER 28P CONNECTOR (Gray) connector.

  • Page 625: Handle Lock Module

    Honda Smart Card Key System HANDLE LOCK MODULE Honda Smart Card Key INDICATOR INPUT VOLTAGE LINE INSPECTION (WITH TEST PROBE) INDICATOR DOES NOT COME ON Remove the screen garnish (page 3-18). COMBINATION METER 28P CONNECTOR Short the combination meter 28P (Gray) connector (Wire side with connector connected) of the wire side and ground using a jumper wire.
  • Page 626 Honda Smart Card Key System Honda Smart Card Key INDICATOR INPUT VOLTAGE LINE INSPECTION (WITH TEST HARNESS) Connect the test harness 21P between the handle lock module 21P (Black) connector and main wire harness (page 23-17). INDICATOR DOES NOT COME ON...
  • Page 627 Honda Smart Card Key System HANDLE LOCK MODULE POWER CIRCUIT INSPECTION (WITH TEST PROBE) Remove the inner cover (page 3-27). HANDLE LOCK MODULE 21P CONNECTOR Turn the ignition switch OFF. (Wire side/female terminals) Disconnect the handle lock module 21P (Black) con- nector (page 23-26).
  • Page 628 Honda Smart Card Key System Turn the ignition switch OFF. TEST HARNESS 21P Check the continuity between the test harness 21P and ground. CONNECTION: 1 – Ground 2 – Ground There is continuity if the system is normal. If there is no continuity, check for open circuit in Green and/or Green/black wire.
  • Page 629 Honda Smart Card Key System HANDLE LOCK MODULE COMMUNICATION LINE INSPECTION (NSS250A: WITH TEST PROBE) Disconnect the following connectors: PCM 21P CONNECTOR – Handle lock module 21P (Black) connector (page (Wire side/female terminals) 23-26) – PCM 21P (Black) connector (page 6-17)
  • Page 630 Honda Smart Card Key System Disconnect the handle lock module 21P (Black) con- HANDLE LOCK MODULE 21P CONNECTOR nector (page 23-26). (Wire side/female terminals) Check the continuity between the handle lock mod- ule 21P and registration 2P connectors. Green/...
  • Page 631 Honda Smart Card Key System EM CONNECTOR LINE INSPECTION (WITH TEST PROBE) Remove the battery cover (page 19-6). 2P CONNECTOR NSS250A shown: Remove the inner cover (page 3-27). Remove the dummy connector. Release the EM 2P (Blue) connector from the battery band.
  • Page 632 Honda Smart Card Key System Connect the test harness 21P between the handle TEST HARNESS 21P lock module 21P (Black) connector and main har- (12) Black/blown ness (page 23-17). Check the continuity between the test harness 21P and EM connector.
  • Page 633 Honda Smart Card Key System Remove the one-way screws. HANDLE LOCK MODULE Remove the screw and handle lock module. SCREW ONE-WAY SCREWS Remove the O-ring and replace it with a new one. O-RING Installation is in the reverse order of removal.

  • Page 634: Led Holder

    Honda Smart Card Key System LED HOLDER INSPECTION Turn the ignition switch OFF. Remove the inner cover (page 3-27). Install the LF antenna (page 23-30). Disconnect the LED holder 3P (Black) connector. 3P CONNECTOR Measure the voltage between the LED holder 3P LED HOLDER 3P CONNECTOR connector of the wire side and ground.
  • Page 635 Honda Smart Card Key System POWER CIRCUIT INSPECTION Push the ignition switch and measure the voltage at RF UNIT 5P CONNECTOR the RF unit 5P connector of the wire side using a (Wire side/female terminals) analog multimeter. CONNECTION: Yellow/red (+) – Ground (–)

  • Page 636: Lf Antenna

    Honda Smart Card Key System REMOVAL/INSTALLATION Remove the luggage lower box (page 3-16). 5P CONNECTOR Disconnect the RF unit 5P (Green) connector and remove the RF unit. Installation is in the reverse order of removal. LF ANTENNA REMOVAL/INSTALLATION Remove the rear meter panel (page 3-22).
  • Page 637 Honda Smart Card Key System INSPECTION (WITH TEST PROBE) Disconnect the handle lock module 21P (Black) con- LF ANTENNA 2P CONNECTOR nector (page 23-26). (Wire side/female terminals) Disconnect the LF antenna 2P (Natural) connector (page 23-30). Blue/ white Check the continuity between the handle lock mod-...

  • Page 638: Seat/Console Box Lock Release

    Honda Smart Card Key System SEAT/CONSOLE BOX LOCK RELEASE BUTTON • For seat/console lock release button removal/installation (page 3-23) INSPECTION Remove the screen garnish (page 3-18). 4P CONNECTOR NSS250A shown: Disconnect the seat/console box lock release button switch 4P (Black) connector.

  • Page 639: Actuator

    Honda Smart Card Key System Measure the voltage between the actuator 2P con- ACTUATOR 2P CONNECTOR nector of the wire side and ground. (Wire side/female terminals) CONNECTION: Red/white (+) – Ground (–) There should be battery voltage at all time.

  • Page 640: Seat Lock Release Actuator

    Honda Smart Card Key System Disconnect the seat lock cable, console box cable BOX LOCK CABLE SEAT LOCK CABLE and mechanical key cable. Remove the console box lock release actuator assembly. Installation is in the reverse order of removal.
  • Page 641 Honda Smart Card Key System Push the registered card key system ON/OFF switch ACTUATOR 2P CONNECTOR ON and Put it within the operating range. (Wire side/female terminals) Check the continuity between the seat lock release actuator 2P connector of the wire side and ground.

  • Page 642: Answer Back Relay

    Honda Smart Card Key System ANSWER BACK RELAY INSPECTION Remove the fuse/relay box cover (page 3-17). ANSWER BACK RELAY Remove the answer back relay. Connect the ohmmeter to the answer back relay connector terminals. CONNECTION: A – B Connect the 12 V battery to the following answer back relay connector terminals.
  • Page 643 Honda Smart Card Key System 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. 23-37...
  • Page 644 maxiscooter-club.ru MEMO...
  • Page 645 24. Honda S Matic System (NSS250A) COMPONENT LOCATION ························ 24-2 COMMUNICATION LINE WITH TEST PROBE ····················································· 24-49 SERVICE INFORMATION ························· 24-3 COMMUNICATION LINE WITH TEST HARNESS ··············································· 24-50 TROUBLESHOOTING ······························· 24-5 MOVABLE DRIVE FACE POSITION SYSTEM LOCATION································· 24-6 SENSOR ·················································· 24-51 SYSTEM DIAGRAM··································...

  • Page 646: Component Location

    Honda S Matic System (NSS250A) COMPONENT LOCATION Honda S Matic System (NSS250A) 3.5 N·m (0.4 kgf·m, 2.6 lbf·ft) 24-2...

  • Page 647: Service Information

    – Movable drive pulley assembly removal/installation (page 11-18) • Honda S Matic System is equipped with the Self-Diagnostic system. If it detects a problem in the system, "F" mark on the gear position indicator on the meter blinks to indicate the problem code.
  • Page 648 Honda S Matic System (NSS250A) TOOLS Remover weight Remover head, 10 mm Remover shaft, 12 mm 07741-0010201 07936-GE00200 07936-1660110 Remover shaft, 10 mm Remover shaft, 12 mm Driver 07936-GE00100 07936-1660120 07749-0010000 Attachment, 22 x 24 mm Imrie diagnostic tester (model 625)

  • Page 649: Troubleshooting

    • Faulty ratio control motor Poor performance at high speed or lack of power • Worn drive belt • Weak driven face spring • Movable drive face not positioned correctly (Faulty Honda S Matic System) • Contaminated pulley faces 24-5...

  • Page 650: System Location

    Honda S Matic System (NSS250A) SYSTEM LOCATION MODE SELECT SWITCH SHIFT SWITCH RATIO CONTROL MOTOR VS SENSOR SENSOR UNIT/TP SENSOR DRIVEN PULLEY SENSOR CKP SENSOR MOVABLE DRIVE FACE POSITION SENSOR 24-6...

  • Page 651: System Diagram

    Honda S Matic System (NSS250A) SYSTEM DIAGRAM METER FUSE 5 A Bl/O IGNITION SWITCH MAIN B FUSE 15 A R/Bl R/Bl ECU,IGN FUSE 10 A ENGINE STOP RELAY BANK ANGLE Bl/O SENSOR BATTERY RATIO MOTOR FUSE 30 A ENGINE STOP...

  • Page 652: Information

    PCM turns on the meter display "F" and stores a DTC in its erasable memory. To reset the Honda S Matic System, turn the igni- tion switch from ON to OFF and back to ON again.
  • Page 653 Connect the HDS pocket tester to the DLC. Turn the ignition switch ON and engine stop switch to " ", and check the DTC and stored data. • Stored data indicates the engine and Honda S Matic System conditions when the first malfunc- tion was detected.
  • Page 654 The number of blinks indicates the stored DTC. For Honda S Matic DTC index (page 24-13). ERASING DTC • When erasing the Honda S Matic System DTC as follows, the PGM-FI DTC would also be erased at the same time, check the MIL blinks and trouble- shoot the PGM-FI system before readout/erasing the Honda S Matic DTC.
  • Page 655 • Always clean around and keep any foreign mate- rial away from the PCM connector before discon- necting it. • A faulty Honda S Matic System is often related to poorly connected or corroded connections. Check those connections before proceeding.
  • Page 656 Honda S Matic System (NSS250A) TEST HARNESS CONNECTION Remove the left body cover (page 3-11). 21P CONNECTOR Turn the ignition switch OFF. Disconnect the PCM 33P (Black) and 21P (Black) con- nectors. 33P CONNECTOR Connect the test harness 33P and 21P between the...

  • Page 657: Honda S Matic Dtc Index

    Honda S Matic System (NSS250A) Honda S Matic DTC INDEX • When the gear position indicator "–" is blinking constantly, but no DTC is indicated or retrievable, refer to serial commu- nication line. – Inspection with test probe: (page 24-49) –...
  • Page 658 • Open circuit in PG3 (Green) wire • Faulty fail-safe relay inside the PCM EEPROM malfunction • Drivable but won’t accelerate • Honda S Matic System initialization failure (Movable drive face not con- 33-2 (33) • movable drive face position sensor or sensor...

  • Page 659: Drivetrain Blink Code (Dtc)

    – PCM 5P (Black) connector – PCM 21P (Black) connector • When removing the movable drive face position sensor, perform the Honda S Matic System initial setting procedure (page 24-61). 1. Movable Drive Face Position Sensor System Inspection Turn the ignition switch ON and engine stop switch to "...
  • Page 660 Honda S Matic System (NSS250A) 4. Ratio Control Motor Output Line Short Circuit Inspection Check the continuity between the PCM 5P con- 5P CONNECTOR nector of the wire side and ground. (Wire side/female terminals) CONNECTION: Black/white – Ground Green/red – Ground...
  • Page 661 Honda S Matic System (NSS250A) 7. Movable Drive Face Position Sensor Installation Inspection Remove the movable drive face position sensor (page 24-51). Check that the slot of the movable drive face Align position sensor and sensor shaft are aligned.
  • Page 662 Honda S Matic System (NSS250A) 10. Movable Drive Face Position Sensor Resistance Inspection 2 Measure the resistance at the movable drive face 3P CONNECTOR position sensor 3P connector terminals of the (Sensor side/male terminals) sensor side by turning the sensor shaft groove of the sensor with your fingers.
  • Page 663 – Movable drive face position sensor (page 24- (GEAR POSITION INDICATOR) – 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 24-61). Test-ride the scooter then retrieve the problem code (page 24-8).
  • Page 664 – Ratio control motor 2P (Black) connector – PCM 5P (Black) connector • When removing the movable drive face position sensor, perform the Honda S Matic System initial setting procedure (page 24-61). 1. RATIO MOTOR Fuse (30 A) Inspection Remove the battery cover (page 19-6).
  • Page 665 Honda S Matic System (NSS250A) 4. Ratio Control Motor Output Line Short Circuit Inspection Check the continuity between the PCM 5P (Black) 5P CONNECTOR connector of the wire side and ground. (Wire side/female terminals) CONNECTION: Black/white – Ground Green/red – Ground Is there continuity? –...
  • Page 666 Honda S Matic System (NSS250A) DTC11-1 (VS sensor no pulse) • Before starting troubleshooting, check for loose or poor contacts on the following connectors, then recheck. – VS sensor 3P (Black) connector – PCM 33P (Black) connector 1. System Inspection Place the scooter on its center stand.
  • Page 667 Honda S Matic System (NSS250A) DTC 13-1 (Driven pulley sensor circuit no signal) • Before starting troubleshooting, check for loose or poor contacts on the following connectors, then recheck. – Driven pulley sensor 10P (Black) connector – PCM 21P (Black) connector •...
  • Page 668 – Ratio control motor 2P (Black) connector – PCM 21P (Black) connector • When removing the movable drive face position sensor, perform the Honda S Matic System initial setting procedure (page 24-61). 1. Movable Drive Face Position Sensor System Inspection Turn the ignition switch ON and engine stop switch "...
  • Page 669 Honda S Matic System (NSS250A) 4. Movable Drive Face Position Sensor Resistance Inspection 2 Measure the resistance at the movable drive face 3P CONNECTOR position sensor 3P connector terminals of the (Sensor side/male terminals) sensor side by turning the sensor shaft groove of sensor with your fingers.
  • Page 670 METER DISPLAY (page 24-52). (GEAR POSITION INDICATOR) Erase the DTC’s from the PCM (page 24-10). Perform the Honda S Matic System initial setting procedure (page 24-61). Test-ride the scooter then retrieve the problem code (page 24-8). Is DTC 29-1 indicated? –...
  • Page 671 Honda S Matic System (NSS250A) 2. 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- Align tion sensor and sensor shaft are aligned.
  • Page 672 METER DISPLAY (page 24-52). (GEAR POSITION INDICATOR) Erase the DTC’s from the PCM (page 24-10). Perform the Honda S Matic System initial setting procedure (page 24-61). Test-ride the scooter then retrieve the problem code (page 24-8). Is DTC 29-2 indicated? –...
  • Page 673 Is the sensor shaft within tolerance? – Install the movable drive face position sensor correctly, then recheck. – Perform the Honda S Matic System ini- tial setting procedure (page 24-61). Replace the PCM with a known good one if DTC 33-2 indicates appear again, and recheck.
  • Page 674 Honda S Matic System (NSS250A) DTC 42-1 (Shift switch) • Before starting troubleshooting, check for loose or poor contacts on the following connectors, then recheck. – Shift switch 3P (Black) connector – PCM 21P (Black) connector 1. Shift Switch Continuity Inspection Remove the inner cover (page 3-27).
  • Page 675 Honda S Matic System (NSS250A) 4. Shift Switch Signal Line Short Circuit Inspection Check the continuity between the shift switch 3P 3P CONNECTOR connector of the wire side and ground. (Wire side/female terminals) CONNECTION: White/blue (+ button) – Ground White/yellow (–...
  • Page 676 Honda S Matic System (NSS250A) 3. Mode Select Switch Signal Line Continuity Inspection Turn the ignition switch OFF. PCM 21P CONNECTOR Disconnect the PCM 21P (Black) connector (page (Wire side/female terminals) 24-12). Check the continuity between the PCM 21P and mode select switch 2P connectors of the wire side.

  • Page 677: Troubleshooting

    – PCM 5P (Black) connector – PCM 21P (Black) connector • When removing the movable drive face position sensor, perform the Honda S Matic System initial setting procedure (page 24-61). 1. Ratio Control Motor Input Voltage Inspection Remove the left body cover (page 3-11).
  • Page 678 Honda S Matic System (NSS250A) 3. Ratio Control Motor Output Line Short Circuit Inspection Check the continuity between the PCM 5P con- 5P CONNECTOR nector of the wire side and ground. (Wire side/female terminals) CONNECTION: Black/white – Ground Green/red – Ground...
  • Page 679 Honda S Matic System (NSS250A) 6. Movable Drive Face Position Sensor Installation Inspection Remove the movable drive face position sensor (page 24-51). Check that the slot of the movable drive face Align position sensor and sensor shaft are aligned.
  • Page 680 Honda S Matic System (NSS250A) 9. Movable Drive Face Position Sensor Resistance Inspection 2 Measure the resistance at the movable drive face 3P CONNECTOR position sensor 3P connector terminals of the (Sensor side/male terminals) sensor side by turning the sensor shaft groove of the sensor with your fingers.
  • Page 681 – Movable drive face position sensor (page 24- (GEAR POSITION INDICATOR) – 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 24-61). Test-ride the scooter then retrieve the problem code (page 24-8).
  • Page 682 – Ratio control motor 2P (Black) connector – PCM 5P (Black) connector • When removing the movable drive face position sensor, perform the Honda S Matic System initial setting procedure (page 24-61). 1. RATIO MOTOR Fuse (30 A) Inspection Remove the battery cover (page 19-6).
  • Page 683 Honda S Matic System (NSS250A) 4. Ratio Control Motor Output Line Short Circuit Inspection Check the continuity between the PCM 5P con- 5P CONNECTOR nector of the wire side and ground. (Wire side/female terminals) CONNECTION: Black/white – Ground Green/red – Ground Is there continuity? –...
  • Page 684 Honda S Matic System (NSS250A) METER DISPLAY "F" 11 BLINKS: VS sensor no signal • Before starting troubleshooting, check for loose or poor contacts on the following connectors, then recheck the "F" blinking. – VS sensor 3P (Black) connector –...
  • Page 685 Honda S Matic System (NSS250A) METER DISPLAY "F" 13 BLINKS: Driven pulley sensor circuit no signal • Before starting troubleshooting, check for loose or poor contacts on the following connectors, then recheck the "F" blinking. – Sub-harness 10P (Black) connector –...
  • Page 686 – Ratio control motor 2P (Black) connector – PCM 21P (Black) connector • When removing the movable drive face position sensor, perform the Honda S Matic System initial setting procedure (page 24-61). 1. Movable Drive Face Position Sensor Installation Inspection Remove the movable drive face position sensor (page 24-51).
  • Page 687 Honda S Matic System (NSS250A) 3. Movable Drive Face Position Sensor Resistance Inspection 2 Measure the resistance at the movable drive face 3P CONNECTOR position sensor 3P connector terminals of the (Sensor side/male terminals) sensor side by turning the sensor shaft groove of sensor with your fingers.
  • Page 688 METER DISPLAY (page 24-52). (GEAR POSITION INDICATOR) Erase the DTC’s from the PCM (page 24-10). Perform the Honda S Matic System initial setting procedure (page 24-61). Test-ride the scooter then retrieve the problem code (page 24-8). Does the meter display "F" blink 29 times? –...
  • Page 689 Is the sensor shaft within tolerance? – Install the movable drive face position sensor correctly, then recheck. – Perform the Honda S Matic System ini- tial setting procedure (page 24-61). Replace the PCM with a known good one if "F" 33 blinks appear again, and recheck.
  • Page 690 Honda S Matic System (NSS250A) METER DISPLAY "F" 42 BLINKS: Shift switch • Before starting troubleshooting, check for loose or poor contacts on the following connectors, then recheck the "F" blinking. – Shift switch 3P (Black) connector – PCM 21P (Black) connector 1.
  • Page 691 Honda S Matic System (NSS250A) 4. Shift Switch Signal Line Short Circuit Inspection Check the continuity between the shift switch 3P 3P CONNECTOR connector of the wire side and ground. (Wire side/female terminals) CONNECTION: White/blue (+ button) – Ground White/yellow (–...
  • Page 692 Honda S Matic System (NSS250A) 3. Mode Select Switch Signal Line Continuity Inspection Connect the test harness 21P to the PCM 21P 2P CONNECTOR (Black) connector (page 24-12). (Wire side/female terminals) Check the continuity between test harness termi- nal and mode select switch 2P connector of the wire side.

  • Page 693: Communication Line With Test

    Honda S Matic System (NSS250A) COMMUNICATION LINE WITH TEST PROBE INSPECTION • If the meter display blinks "–", perform the fol- lowing inspection. • Before starting troubleshooting, check for loose or poor contacts on the following connectors, then recheck.

  • Page 694: Communication Line With Test

    Honda S Matic System (NSS250A) COMMUNICATION LINE WITH TEST HARNESS INSPECTION • If the meter display blinks "–", perform the fol- lowing inspection. • Before starting troubleshooting, check for loose or poor contacts on the following connectors, then recheck the "–" blinking.

  • Page 695: Movable Drive Face Position

    • Movable drive face position sensor malfunction ("F" 29 blinks) can be detected after starting the engine. • When removing the movable drive face position sensor, perform the Honda S Matic System initial setting procedure (page 24-61). Remove the left crankcase cover (page 11-7). 3P CONNECTOR Yellow/ Turn the ignition switch OFF.

  • Page 696: Ratio Control Motor

    TORQUE: 3.5 N·m (0.4 kgf·m, 2.6 lbf·ft) Connect the movable drive face position sensor 3P (Black) connector. Perform the Honda S Matic System initial setting procedure (page 24-61). Install the left crankcase cover (page 11-9). 3P CONNECTOR RATIO CONTROL MOTOR REMOVAL Remove the luggage lower box (page 3-16).
  • Page 697 Honda S Matic System (NSS250A) Remove the bolts and stay. STAY BOLTS Remove the ratio control motor and O-ring. O-RING RATIO CONTROL MOTOR INSTALLATION Apply oil to a new O-ring and install it to the ratio Be sure that the control motor groove.

  • Page 698: Movable Drive Face Position Sensor Shaft/Reduction Gear

    SENSOR SHAFT/REDUCTION GEAR 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). Remove the movable drive face position sensor SENSOR PLATE (page 24-51).
  • Page 699 Honda S Matic System (NSS250A) REDUCTION GEAR REMOVAL Remove the movable drive face position sensor BOLTS (page 24-54). Remove the bolts and ratio control gear holder. GEAR HOLDER Remove the reduction gear B. REDUCTION GEAR B Remove the bolts and reduction gear A holder.
  • Page 700 Honda S Matic System (NSS250A) REDUCTION GEAR Check the reduction gear A and B for wear or dam- REDUCTION GEAR A REDUCTION GEAR B age. Replace them if necessary. REDUCTION GEAR A, B BEARING INSPECTION/ REPLACEMENT Turn the inner race of each bearing with your finger.
  • Page 701 Honda S Matic System (NSS250A) LEFT CRANKCASE SIDE Remove the reduction gear A and B bearings using GEAR B BEARING GEAR A BEARING special tools. TOOLS: Remover shaft, 10 mm 07936-GE00100 REMOVER SHAFT Remover head, 10 mm 07936-GE00200 Remover weight...
  • Page 702 Honda S Matic System (NSS250A) REDUCTION GEAR INSTALLATION Install the reduction gear A. BOLTS REDUCTION GEAR A Align Install the gear A holder aligning its hole with the crankcase boss. Tighten the bolts. REDUCTION GEAR A GEAR A HOLDER Install the reduction gear B.
  • Page 703 Apply oil to a new O-ring and install it into the sen- O-RING SENSOR SHAFT sor plate groove. Install the sensor plate. SENSOR PLATE Install the movable drive face position sensor (page 24-52). Perform the Honda S Matic System initial setting procedure (page 24-61). 24-59...

  • Page 704: Driven Pulley Sensor

    Honda S Matic System (NSS250A) DRIVEN PULLEY SENSOR DRIVEN PULLEY SENSOR PLATE REMOVAL/INSTALLATION Remove the driven pulley (page 11-27). SENSOR PLATE Remove the bolts and driven pulley pulser ring. Installation is in the reverse order of removal. TORQUE: Driven pulley pulser ring bolt: 9 N·m (0.9 kgf·m, 6.6 lbf·ft)
  • Page 705 • Before initializing the Honda S Matic System, warm up the engine. • Be careful when initializing the Honda S Matic System. The rear wheel rotates in varied speed during initialization process. 1. Turn the ignition switch OFF and release the parking brake.
  • Page 706 Honda S Matic System (NSS250A) 5. Check that the "AM 1" is blinking on the gear GEAR POSITION INDICATOR position indicator on the meter. Rotate the throttle grip from the fully closed posi- tion to the fully opened position, then back to the fully closed position.
  • Page 707 25. WIRING DIAGRAMS NSS250S ··················································· 25-3 NSS250A··················································· 25-4 25-1...
  • Page 708 maxiscooter-club.ru 26. TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO POOR PERFORMANCE AT HIGH START ······················································· 26-2 SPEED ······················································· 26-6 ENGINE LACKS POWER ·························· 26-3 POOR HANDLING ···································· 26-7 POOR PERFORMANCE AT LOW AND IDLE SPEED························································ 26-5 26-1...
  • Page 709 maxiscooter-club.ru TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START TROUBLESHOOTING 1. Spark Plug Inspection Remove and inspect spark plug. Is spark plug in good condition? – GO TO STEP 2. – • Incorrect spark plug heat range • Incorrect spark plug gap •...
  • Page 710 Does the engine speed change according to acceleration? – GO TO STEP 4. – • 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? – GO TO STEP 5.
  • Page 711 maxiscooter-club.ru TROUBLESHOOTING 7. Ignition Timing Inspection Check the ignition timing. Is the ignition timing within specification? – GO TO STEP 8. – • Faulty PCM/ECM • Faulty CKP sensor • Improper valve timing 8. Cylinder compression Inspection Test the cylinder compression. Is the compression within specification? –...
  • Page 712 maxiscooter-club.ru TROUBLESHOOTING POOR PERFORMANCE AT LOW AND IDLE SPEED 1. Spark Plug Inspection Remove and inspect the spark plug. Is the spark plug in good condition? – GO TO STEP 2. – • Plug not serviced frequently enough • Incorrect spark plug heat range •...
  • Page 713 maxiscooter-club.ru TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED 1. Ignition Timing Inspection Check the ignition timing. Is the ignition timing within specification? – GO TO STEP 2. – • Faulty PCM/ECM • Faulty CKP sensor • Improper valve timing 2. Fuel Line Inspection Disconnect the fuel hose at the fuel pump.
  • Page 714 maxiscooter-club.ru TROUBLESHOOTING POOR HANDLING Steering is heavy • Steering stem adjusting nut too tight • 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 •...
  • Page 715 maxiscooter-club.ru MEMO...
  • Page 716 CYLINDER/PISTON SPECIFICATIONS ························· 1-8 ANSWER BACK RELAY·············································23-36 DELAY VALVE ··························································· 17-27 BALANCER GEAR······················································14-18 DIAGNOSTIC CODE INDICATION BANK ANGLE SENSOR···············································6-92 (Honda Smart Card Key System)······························· 23-8 BATTERY······································································19-6 DRIVE BELT BATTERY/CHARGING SYSTEM SPECIFICATIONS ···1-11 MAINTENANCE ······················································ 4-15 BELT CASE AIR CLEANER ··········································4-15 DRIVE PULLEY (NSS250A) ·······································...
  • Page 717 HEADLIGHT ································································· 22-7 ON THE COMPRESSION STROKE ······························ 9-6 HEADLIGHT AIM ························································· 4-21 RADIATOR ··································································· 7-14 Honda S Matic DTC INDEX ······································ 24-13 RADIATOR COOLANT················································· 4-13 Honda S Matic System (NSS250A) ····························· 2-7 RADIATOR RESERVE TANK ······································· 7-17 Honda S Matic System INITIAL SETTING RATIO CONTROL MOTOR ········································...
  • Page 718 FRONT WHEEL/SUSPENSION/STEERING············ 15-5 BATTERY/CHARGING SYSTEM·····························19-2 ELECTRIC STARTER ···············································21-2 Honda S Matic System ·········································· 24-5 Honda S Matic System···········································24-7 Honda Smart Card Key System ·························· 23-10 Honda Smart Card Key System·····························23-4 HYDRAULIC BRAKE ··············································· 17-6 IGNITION SYSTEM ·················································20-2 IGNITION SYSTEM················································· 20-4 SYSTEM FLOW PATTERN (COOLING SYSTEM) ········7-2...

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