Table Of Contents - Honda NSS250/A Service Manual

Table of Contents

A Few Words About Safety2
How To Use This Manual3
Contents3
Symbols4
General Information5
Service Rules5
Model Identification5
Specifications7
General Item7
Lubrication System Item9
Fuel System Item9
Cooling System Item9
Cylinder Head/Valves Item10
Piston/Cylinder Item10
Drive Pulley/Driven Pulley/Clutch Item11
Final Reduction Item11
Alternator/Starter Clutch Item11
Crankshaft/Crankcase Item11
Front Wheel/Suspension/Steering Item12
Rear Wheel/Suspension Item12
Hydraulic Brake Item12
Battery/Charging System Item13
Ignition System Item13
Electric Starter Item13
Lights/Meters/Switches Item14
Torque Values15
Engine15
Frame16
Tools18
Lubrication & Seal Points20
Cable & Harness Routing, Nss25022
Cable & Harness Routing, Nss250A28
Cable & Harness Routing, Nss250S/As34
Emission Control System38
Source Of Emissions38
Evaporative Emission Control System39
Noise Emission Control System39
Exhaust Emission Control System40
Pulse Secondary Air Injection System40
Emission Control Information Labels41
Vacuum Hose Routing Diagram Label ('01-'04 Only)41
Body Panel Locations42
Body Panel Removal Chart42
Frame/Body Panels/Exhaust System43
Service Information43
Trim Clip44
Seat45
Removal45
Installation45
Floor Mat45
Floor Skirt46
Rear Spoiler (Nss250/A Only)46
Body Cover (Nss250/A Only)47
Rear Center Cover47
Disassembly/Assembly48
Upper Luggage Box49
Lower Luggage Box50
Windshield Garnish51
Windshield51
Backrest (Nss250S/As Only)52
Grab Rail (Nss250S/As Only)52
Front Cover53
Front Meter Visor Removal/Installation53
Front Lower Cover54
Inner Cover55
Under Cover55
Handlebar Cover56
Muffler56
Muffler Protector57
Maintenance59
Maintenance Schedule61
Fuel Line62
Throttle Operation62
Air Cleaner63
Crankcase Breather64
Spark Plug64
Valve Clearance65
Engine Oil66
Engine Oil Strainer Screen67
Engine Idle Speed68
Radiator Coolant68
Secondary Air Supply System70
Final Drive Oil70
Level Check70
Oil Change71
Brake Fluid72
Brake Pad Wear73
Brake System73
Brake Lock Operation74
Headlight Aim74
Side Stand74
Front Suspension75
Rear Suspension75
Nuts, Bolts, Fasteners75
Wheels/Tires76
Steering Head Bearings76
Lubrication System Diagram78
Lubrication System79
Oil Pump80
Fuel System View84
Fuel System85
Air Cleaner Housing87
Carburetor Removal88
Carburetor Disassembly89
Se Valve90
Vacuum Chamber91
Float Chamber92
Air Cut-Off Valve93
Carburetor Cleaning93
Carburetor Assembly94
Float Level Inspection95
Carburetor Installation99
Starting Enrichment (Se) Valve101
Resistance Inspection101
Operation Inspection101
Pilot Screw Adjustment102
Idle Drop Procedure102
High Altitude Adjustment103
System Inspection104
Pair Check Valve Inspection105
Pair Control Valve Removal/Installation106
Evaporative Emission (Evap) Canister Removal/Installation107
Evaporative Emission (Evap) Purge Control Valve107
Fuel Tank108
System Float Pattern110
Cooling System111
System Testing113
Coolant (Hydrometer Test)113
Coolant Specific Gravity Chart113
Radiator Cap/System Pressure Inspection114
Coolant Replacement114
Replacement/Air Bleeding115
Thermostat116
Water Pump117
Mechanical Seal Inspection117
Mechanical Seal Replacement119
Radiator123
Radiator Reserve Tank126
Engine Removal/Installation128
Engine Removal130
Engine Hanger Bracket133
Tension Rod134
Sub-Bracket135
Engine Installation138
Cylinder Head/Valves View142
Cylinder Head/Valves143
Cylinder Compression Test145
Cylinder Head Cover Removal145
Camshaft Removal146
Cylinder Head Removal148
Cylinder Head Disassembly149
Valve Springs150
Valve Stem/Valve Guide150
Valve Guide Replacement151
Valve Seat Inspection/Refacing152
Valve Seat Refacing153
Cylinder Head Assembly155
Cylinder Head Installation156
Camshaft Installation158
Cylinder Head Cover Installation160
Cylinder/Piston View162
Cylinder/Piston163
Cylinder/Piston Removal165
Piston/Piston Pin166
Stud Bolt Replacement168
Piston Ring Installation168
Cylinder/Piston Installation169
Drive Pulley/Driven Pulley/Clutch View172
Drive Pulley/Driven Pulley/Clutch173
Left Crankcase Cover175
Belt Case Air Cleaner175
Drive Pulley177
Drive Belt178
Weight Roller178
Movable Drive Face178
Clutch/Driven Pulley181
Clutch Disassembly182
Driven Pulley Disassembly183
Driven Face Bearing Replacement183
Drive Face Spring185
Drive Face185
Movable Driven Face185
Driven Pulley Assembly186
Clutch Assembly187
Clutch/Driven Pulley Assembly188
Final Reduction View190
Final Reduction191
Final Reduction Disassembly193
Transmission Disassembly193
Drive Shaft Removal193
Final Reduction Inspection194
Bearing Replacement195
Left Crankcase195
Transmission Cover197
Final Reduction Assembly198
Driveshaft Installation198
Transmission Assembly198
Alternator/Starter Clutch View200
Alternator/Starter Clutch201
Alternator Stator202
Right Crankcase Cover Removal202
Stator?Ignition Pulse Generator Removal/Installation203
Right Crankcase Cover Installation203
Flywheel/Starter Clutch204
Crankshaft/Crankcase View210
Crankshaft/Crankcase211
Crankcase Separation212
Crankshaft Inspection213
Crankcase Assembly214
Front Wheel/Suspension/Steering View218
Front Wheel/Suspension/Steering219
Front Wheel221
Wheel Bearing222
Fork226
Fork Spring229
Fork Tube/Bottom Case229
Fork Piston230
Steering Handle234
Steering Stem241
Handle Cover (Nss250S/As Only)246
Rear Wheel/Suspension View248
Rear Wheel/Suspension249
Rear Wheel/Swingarm251
Swingarm Bearing Replacement252
Rear Shock Absorber255
Hydraulic Brake View258
Hydraulic Brake259
Brake Fluid Replacement/Air Bleeding262
Brake Fluid Draining262
Brake Fluid Filling/Air Bleeding263
Fluid Feeding265
Air Bleeding266
Brake Pad/Disc267
Brake Pad Replacement267
Brake Disc Inspection271
Front Master Cylinder271
Rear Master Cylinder275
Delay Valve280
Front Brake Caliper281
Rear Brake Caliper285
Parking Brake291
Parking Brake Lever Link292
Parking Brake Cable292
Battery/Charging System View294
Battery/Charging System295
Battery298
Voltage Inspection298
Battery Testing299
Battery Charging300
Charging System Inspection301
Current Leakage Test301
Charging Voltage Inspection301
Alternator Charging Coil302
Regulator/Rectifier302
Wire Harness Inspection302
Battery Line302
Ground Line303
Charging Coil Line303
Ignition System View304
Ignition System305
Ignition System Inspection307
Ignition Coil Primary Peak Voltage307
Ignition Pulse Generator Peak Voltage308
Ignition Coil309
Ignition Timing309
Throttle Position (Tp) Sensor310
Input Voltage Inspection311
Ect Sensor312
Continuity Inspection312
Unit Inspection312
Electric Starter View314
Electric Starter315
Starter Motor318
Starter Relay Switch325
Ground Line Inspection325
Lights/Meters/Switches View328
Lights/Meters/Switches329
Bulb Replacement331
Headlight331
Front Turn Signal/Running Light331
Rear Turn Signal, Brake/Tail Light331
Rear Turn Signal332
Brake/Tail Light332
License Light332
Indicator And Meter333
Luggage Box Instrument Light333
Combination Meter333
Tachometer Inspection333
Limit Switch337
Brake Light Switch338
Ignition Switch338
Handlebar Switch339
Right Handlebar Switch339
Left Handlebar Switch339
Trunk Switch340
Fan Motor Switch340
Fan Motor Does Not Stop340
Fan Motor Does Not Start340
Coolant Temperature Gauge/Instrument Ect Sensor341
Thermosensor Inspection342
Fuel Pump343
Discharge Volume Inspection344
Fuel Pump Flow Capacity344
Fuel Gauge/Fuel Level Sensor345
Fuel Level Sensor Inspection346
Side Stand Switch347
Horn348
Abs (Anti-Lock Brake System) View350
Abs (Anti-Lock Brake System)351
Self-Diagnosis Procedure352
Self-Diagnosis Memory Reset Procedure353
Abs Indicator Failure Code354
Abs Indicator Not Blinks355
Abs Indicator Stays Lit356
Abs Indicator Blinks359
Abs Indicator 11 Blinks (Front Wheel Speed Sensor)360
Abs Indicator 12 Blinks (Front Wheel Speed Sensor)362
Abs Indicator 13 Blinks (Rear Wheel Speed Sensor)363
Abs Indicator 14 Blinks (Rear Wheel Speed Sensor)365
Abs Indicator 21 Blinks (Front Pulser Ring)366
Abs Indicator 23 Blinks (Rear Pulser Ring)366
Abs Indicator 31, 32, 33, 34, 37 And 38 Blinks (Solenoid Valve)367
Abs Indicator 41 Blinks (Front Wheel Lock)367
Abs Indicator 43 Blinks (Rear Wheel Lock)367
Abs Indicator 51 Blinks (Motor & Pump Lock)368
Abs Indicator 52 Blinks (Motor & Pump Off)369
Abs Indicator 53 Blinks (Motor & Pump On)369
Abs Indicator 54 Blinks (Failsafe Relay)369
Abs Indicator 61 And 62 Blinks (Failsafe Relay Voltage)370
Abs Indicator 71 Blinks (Incorrect Tire Size)370
Abs Indicator 81 Blinks (Cpu)370
Front Pulser Ring371
Rear Pulser Ring371
Front Wheel Speed Sensor372
Rear Wheel Speed Sensor373
Abs Modulator375
Wiring Diagrams379
'01-'03 Standard Type379
'01-'03 Abs Type380
After '03 Standard Type381
After '03 Abs Type382
Technical Features383
Auto Adjust Brake Lock Rear Caliper383
Auto Adjust Mechanism383
Operation385
Parking Brake Mechanism386
Abs Location387
Abs Diagram389
System Construction390
Wheel Speed Sensor/Pulser Ring390
Reservoir390
Solenoid Valve (In/Out)390
Abs Basic Function391
Self-Diagnosis Function391
Fail Safe Function391
Fluid Pressure Control392
Lick-Back392
When Abs Is Working392
Troubleshooting395
Engine Lacks Power396
Poor Performance At Low And Idle Speeds397
Poor Performance At High Speed398
Index399