Page 2 GENERAL INFORMATION SERVICE RU LES 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 3 GENERAL INFORMATION SERIAL NUMBERS The Vehicle Identification Number (V.I.N) is stamped on the left side of r--- -- -- -- -- -- -- -- -- -, the frame. VEHICLE IDENTIFICATION NUMBER The engine serial number is stamped on the left side of the b elt case.
Page 4 GENERAL INFORMATION LABELS The color label is attached as shown. When ordering color-coded parts, ,--- -- -- -- -- -- -- -- -- -, always specify the designated color code. COLOR LABEL The safety certification label is attached on the left side of the frame. SAFETY CERTIFICATION LABEL The Emission Control Information Label (After '05 model only) is ,--- -- -- -- -- -- -- -- -, attached on the right side of the frame.
Page 5 GENERAL INFORMATION G ENE RAL SPECIFICATIONS ITEM SPECIFICATION DIME NSIONS Overal l length 1 , 860 mm (73.2 in) Overal l width 735 mm (28.9 in) Overall height 1 ,025 mm (40.4 in) Wheelbase 1 ,265 mm (49.8 in) Seat height 735 mm (28.9 in) Ground clearance 145 mm (5.7 in)
Page 6 Fully open 100 'C (212 'F) Valve lift 8 mm (0.3 in) minimum Standard coolant concentration 1 : 1 mixture with soft water Revised: September 2006, 2003·2007 NPS50 ©2006 American Honda Motor Co,, Inc.· All Rights Reserved MSV 11664 (0609)
Page 7 GENERAL INFORMATION CYLI NDER H EAD/VALVES SPECI FICATIONS Unit · mm (in) ITEM STANDARD SERVICE LIMIT Cylinder compression 1,393 kPa (14.2 kgf/cm', 202 psi) at 1,500 rpm 0.05 (0.002) Cylinder head warpage 0.10 ± 0.03 (0.004 ± 0.001) Valve, valve Valve clearance guide 0.19 + 0.03 (0.007 + 0.001 )
Page 8 GENERAL INFORMATION CRANKSHAFT /PISTON/CYLINDER SPECIFICATIONS Unit · mm (in) ITEM STANDARD SERVICE LIMIT Crankshaft Connecting rod side clearance 0.1 0 - 0.40 (0.004- 0.016) 0.60 (0.024) Connecting rod radial clearance 0.016 (0.0002 0.004 0.0006) 0.05 (0.002) Runout 0.10 (0.004) J.D. 37.810 (1.4882 Cylinder 37.800...
Page 9 GENERAL INFORMATION BATTERY /CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Battery Capacity 6 Ah Current leakage 0.1 rnA max. Voltage (20 'C/68 'F) Fully charged 13.0 - 13.2V Needs charging Below 12.3V o.sn Charging current Normal 0.6AI5 - 10h Quick 3AI1 h Capacity 190 W/5,000 rpm Alternator...
Page 10 GENERAL INFORMATION STANDARD TORQU E VALU ES TORQUE TORQUE FASTENER TYPE FASTENER TYPE N·m (kgf·m, lbf . ft) N·m (kgf·m, lbf . ft) 5.2 (0.53, 3.8) 5 mm screw 4.2 (0.43, 3.1 ) 5 mm hex bolt and nut 6 mm hex bolt and nut 9.8 (1.0, 7) 6 mm screw 8.8 (0.9, 6.5)
Page 11 GENERAL INFORMATION KICKSTARTER/DRIVE PULLEY /DRIVEN PULLEY/CLUTCH THREAD TORQUE Q ' T V ITEM REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) Clutch outer nut 39 (4.0, 29) Drive pulley face nut 3 2 (3.3, 24) NOTE 1 FINAL REDUCTION THREAD TORQUE Q ' T V ITEM REMARKS DIA.
Page 12 GENERAL INFORMATION LIGHTS/METERS/SWITCHES THREAD TORQUE Q ' TY ITEM REMARKS N·m (l<gf·m, lbf . ft) DIA. (mm) Turn signal light mounting nut 9.8 (1.0, 7 ) OTHERS THREAD TORQUE Q'T Y ITEM REMARKS N·m (kgf·m, lbf . ft) DIA. (mm) 44 (4.
Page 13 GENERAL INFORMATION L U BRICATION & SEAL POI NTS ENGINE LOCATION MATERIAL REMARKS ECT sensor threads Liquid sealant Do not apply sealant to the (Three Bond 12078 o r equiv- sensor threads head. alent) Crankcase mating surface See page 13-11 Transmission case mating surface See page 11-11 Kickstarter spindle seating surface...
Page 14 GENERAL INFORMATION FRAME LOCATION MATERIAL REMARKS Front wheel dust seal lips Multi-purpose grease Speedometer gear teeth Front brake panel dust seal lips Brake cams Brake panel anch o r pins Apply grease 6.5 - Bg. Fork spring taper area Fork rebound spring Fork guide bush ing inner surface Fork dust seal lips Fill up 1.5 - 2g.
Page 15 GENERAL INFORMATION CABLE & HARN ESS ROUTING '03 - '05 MODEL: REAR BRAKE LIGHT LEFT HANDLEBAR SWITCH WIRE SWITCH WIRE FRONT BRAKE CABLE REAR BRAKE CABLE FRONT HANDLEBAR RIGHT HANDLEBAR SWITCH WIRE TURN SIGNAL INDICATOR WIRE SPEEDOMETER STAY A: RIGHT HANDLEBAR SWITCH WIRE SPEEDOMETER CABLE B: FRONT BRAKE LIGHT SWITCH WIRE C: THROTTLE CABLE...
Page 16 GENERAL INFORMATION AFTER '05 MODEL: LEFT HANDLEBAR WIRE REAR BRAKE CABLE REAR BRAKE LIGHT SWITCH WIRE REAR BRAKE CABLE RIGHT H AN DLEBAR SWITCH WIRE TURN SIGNAL INDICATOR WIRE SPEEDOMETER STAY A: RIGHT HANDLEBAR SWITCH WIRE SPEEDOMETER CABLE B: FRONT BRAKE LIGHT SWITCH WIRE C: THROTTLE CABLE D: FRONT BRAKE CABLE E: REAR BRAKE LIGHT SWITCH WIRE...
Page 17 GENERAL INFORMATION '03 - '05 MODEL: SPEEDOMETER CABLE FRONT BRAKE CABLE REAR BRAI<E CABLE GROUND CABLE STAY I< CLAMP (ATWHITE TAPE) WIRE A, B, E, F, H, I, A: RIGHT HAN DLEBAR SWITCH WIRE B: FRONT BRAKE LIGHT SWITCH WIRE C: THROTTLE CABLE FRONT BRAKE CABLE D: FRONT BRAKE CABLE...
Page 18 GENERAL INFORMATION AFTER '05 MODEL: FRONT BRAKE CABLE THROTTLE CABLE GROUND CABLE REAR BRAKE CABLE STAY FRONT CLAMP (ATWHITE TAPE) WIRE A. B, E, F, H, J FRONT BRAKE CABLE A: RIGHT HANDLEBAR SWITCH WIRE B: FRONT BRAI < E LIGHT SWITCH WIRE C: THROTTLE CABLE FRONT BRAKE CABLE D: FRONT BRAKE CABLE...
Page 19 GENERAL INFORMATION E N G I N E CONTROL RESISTOR THROTTLE CABLE HORN WIRES FRONT FRONT HEADLIGHT/H ORN TURN SIGNAL LIGHT 6P CONNECTOR WIRE CONNECTORS 1 - 1 9...
Page 20 GENERAL INFORMATION MAIN RELAY LOAD CUT RELAY FUEL RESERVE FUSE BOX I G N ITION SWITCH INDICATOR HIGH BEAM IN DICATOR LIGHT LED DRIVE UNIT 6P CONNECTOR FUEL RESERVE INDICATOR 2P CONNECTOR SERVICE CHECK 2P CONNECTOR BATIERY TURN SIGNAL RELAY 1 -20...
Page 21 GENERAL INFORMATION '03 - '05 MODEL: FUEL FILTER AIR SUPPLY HOSE THROTTLE CABLE FUEL HOSE AFTER '05 MODEL: FUEL FILTER FUEL PUMP WIRE FU EL FILTER AIR SUPPLY HOSE THROTTLE CABLE FUEL HOSE 1 -2 1...
Page 22 GENERAL INFORMATION '03 - '05 MODEL: FUEL TANK UNDER COVER · - · - --, REAR BRAI < E CABLE AIR SUPPLY HOSE THROTTLE CABLE FUEL RESERVE SENSOR 3P CONNECTOR MAIN WIRE HARNESS AFTER '05 MODEL: FUEL TANK UNDER COVER REAR BRAKE CABLE AIR S UPPLY HOSE (WITH HOSE PLUG)
Page 23 GENERAL INFORMATION '03 - '05 MODEL: ECT SEN SOR PAIR CON TROL VALVE VACUUM HOSE PAIR CHE K VALVE BOTTOM 1 -23...
Page 24 GENERAL INFORMATION AFTER '05 MODEL: WATER HOSE ECT SENSOR 0 w=== PAIR CHECK VALVE BOTT O M 1 -24...
Page 25 GENERAL INFORMATION IGNITION COIL JOn+ FRONT ALTERNATOR/ STARTER WIRES BOTI O M 1 -25...
Page 26 GENERAL INFORMATION '03 - '05 MODEL: RADIATOR RESERVE TANK ER HOSE CARBURETOR VACUUM PISTON HOSE ALTERNATOR/ STARTER WIRES (AT WHITE TAPE) GROUND WIRE TH ROTTLE CABLE THROTTLE POSITION SENSOR 3P CONNECTOR VACUUM HOSE GROUND WIRE CARBURETOR STARTING ENRICHMENT (SE) VACU UM ECT SENSOR WIRE VALVE 2P CONNECTOR PISTON HOSE...
Page 27 GENERAL INFORMATION AFTER '05 MODEL: RADIATOR RESERVE AIR SUCTION TAN K BREA HOSE HOSE MAIN WIRE HARN ESS ALTERNATOR/ STARTER WIRES (AT WHITE TAPE) GROUND WIRE EN GINE BREATHER HOSE ECT SEN SOR WIRE THROTTLE CABLE THROTTLE POSITION SEN SOR 3P CONN ECTOR ECT SEN SOR WIRE STARTING CARBURETOR...
Page 28 GENERAL INFORMATION '03 - '05 MODEL: CARBURETOR VACUUM PISTON HOSE ENGINE BREATHER H OS E MAIN WIRE HARNESS SPARK PLUG WIRE WIRE HARNESSES RADIATOR RESERVE TANK BREATHER HOSE RADIATOR RESERVE TANK FUEL PUMP WIRE IGNITION COIL WIRE BREATHER HOSE RADIATOR RESERVE FUEL HOSE TANK BREATHER HOSE 1 -28...
Page 29 GENERAL INFORMATION AFTER '05 MODEL: CARBURETOR VACUUM PISTON HOSE ENGINE BR ATHER HOSE MAIN WIRE HARNESS AIR SUCTION HOSE RADIATOR RESERVE TAN I< BREATHER HOSE FUEL PUMP WIRE IGNITION COIL WIRE WIRE HARNESSES 1 -29...
Page 30 GENERAL INFORMATION AFTER '05 MODEL: MAIN WIRE HARNESS PCV CONTROL SOLENOID VALVE AIR SUCTION AIR SUPPLY H OSES ENGINE BREATH ER H OSE 1 -30...
Page 31 GENERAL INFORMATION '03 - '05 MODEL: A: RIGHT TURN SIGNAL LIGHT WIRES 8: LEFT TURN SIGNAL LIGHT WIRES TAIL LIGHT WIRES AFTER '05 MODEL: A: RIGHT TURN SIGNAL LIGHT WIRES 8: LEFT TURN SIGNAL LIGHT WIRES TAIL LIGHT WIRES AIR SUCTION H OSES 1 -3 1...
Page 32 GENERAL INFORMATION E N G I N E BREATHER DRAIN H OSE · · '/ '\=: !LJC /� REAR BRAKE CABLE 1 -32...
Page 33 GENERAL INFORMATION PULSE GENERATOR WIRE 1 -33...
Page 34: Emission Control Systems
Carbon monoxide does not react in th e same way, but it is toxic. Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarbons.
Page 35 GENERAL INFORMATION '05 model) EXHAUST EMISSION CONTROL SYSTEM ('03 SECONDARY AIR SUPPLY SYSTEM The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system.
Page 36: General Information
GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (After '05 model) SECONDARY AIR SUPPLY SYSTEM The secondary air supply system introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system. This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor.
Page 37 2 . TECH N ICA L FEATURES PCV (Positive Crankcase Venti l ation) (Afte r ' 05 mod e l ) ...........
Page 38 TECHNICAL FEATURES PCV (Positive Crankcase Ventilation) (After '05 model) This system ventilates the crankcase b y injecting fresh air. Properly ventilating t h e crankcase prevents t h e stagnant blow by gas that contains gasoline o r water vapor from contaminating the engine oil under the driving conditions that result in low engine oil temperature.
Page 39: Table Of Contents
3. FRAME/BODY PANELS/EXHAUST SYSTEM FRONT COVER ···············································3-6 BODY PANEL LOCATIONS ......3-2 FLOOR STEP ···················································3-7 SERVICE INFORMATION ······························ 3-3 TROUBLESHOOTING ········ ··························· · 3-3 UNDER COVER ···············································3-8 SEAT ······························································· 3-4 REAR FENDER ················································3-8 SEAT RAIL ······················································ 3-5 MU FFLER ························································3-9 INNER COVER ················································...
Page 40: Body Panel Locations
FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS SEAT RAIL FRONT COVER MUFFLER INNER COVER...
Page 41: Service Information
FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL • This section covers removal and installation of the body panels, exhaust system and seat rail. • Always replace the exhaust pipe gasket with a new one after loosening or removing the exhaust pipe joint nuts. •...
Page 42 FRAME/BODY PANELS/EXHAUST SYSTEM S EAT REMOVAL Open the seat by unhooking the seat hook. SEAT Remove the two nuts and seat. SEAT INSTALLATION Install the seat to the frame hooks and seat hinges ,--- -- -- -- -- -- -- -- -- -, HOD I <...
Page 43 FRAME/BODY PANELS/EXHAUST SYSTEM SEAT RAIL REMOVAL/INSTALLATION Remove the six bolts and seat rail. Installation is in the reverse order of removal. I N N ER COVER REMOVAL Be careful not to Remove the four screws and inner cover. SCREW damage the tabs and slots.
Page 44: Front Cover
FRAME/BODY PANELS/EXHAUST SYSTEM FRONT COVER REMOVAL/INSTALLATION Remove the inner cover (page 3-5). Disconnect the headlight/horn 6P and turn signal light connectors. Remove the three bolts and headlight bracket assembly. Remove the two screws and front cover. HEADLIGHT BRACKET ASSEMBLY BOLTS FRONT COVER Install the removed parts in the reverse order of removal.
Page 45 FRAME/BODY PANELS/EXHAUST SYSTEM FLOOR STEP REMOVAL Remove the following: - Seat rail (page 3-5). - Inner cover (page 3-5). Remove the front mud guard. Remove the four screws, eight bolts/washers and floor step. FRONT MUD GUARD BOLTS/WASH ERS SCREWS INSTALLATION Be careful not to Install the floor step onto the frame.
Page 46: Rear Fender
FRAME/BODY PANELS/EXHAUST SYSTEM UNDER COVER REMOVAL/INSTALLATION Remove the following: - Floor step (page 3-7). - Fuel tank (page 6-28). Be careful not to Open the fuel pump lid by releasing its hooks. Disconnect the fuel pump 2P connector. damage the hooks. 2P CONNECTOR Release the main wire harness and throttle cable from the guide of the under cover.
Page 47 FRAME/BODY PANELS/EXHAUST SYSTEM M U FFLER REMOVAL Remove the two exhaust pipe joint nuts. NOTE: Remove the fender bolt, two muffler mounting bolts and muffler. • • Muffler mounting bolts; Upper: Short Lower: Long Remove the gasket. INSTALLATION Replace the gasket with a new one. Installation is in the reverse order of removal.
Page 49: Specifications
After draining 0.7 liter (0.7 US qt, 0.6 1mp qt) At disassembly R ecommended engine oil Pro Honda GN4 4-stroke oii (U.S.A. and Canada) or an equivalent motor oil API service classification: SG or higher JASO T 903 standard: MA...
Page 50 Should be serviced by an authorized Honda scooter dealer, unless the owner has proper tools and service data and is mechanically qualified. In the interest of safety, we recommend these items be serviced only by an authorized Honda scooter dealer. NOTES: 1 .
Page 51: Throttle Operation
MAINTENANCE F U E L LINE Remove t h e floor step (page 3-7). Check the fuel lines for deterioration, damage or leakage. Visually inspect the fuel filter for contamination. Replace the fuel lines or filter if necessary. THROTTLE OPERATION Check the throttle cable for any deterioration or damage.
Page 52: Air Cleaner
MAINTENANCE Major adjustment is made with the lower adjuster. Loosen the lock nut, turn the adjusting nut as required and tighten the lock nut. Recheck the throttle operation. NOTE: • AIR CLEANER The viscous paper element type air cleaner can not be cleaned because the element contains a dust adhesive.
Page 53: Spark Plug
NOTE: MAINTENANCE • ENGINE BREATHER Service more frequently when ridden in rain, at full throttle, or after the motorcycle is washed or overturned. Service if the deposit level can be seen in the transparent section of the drain hose. Remove the engine breather drain hose plug from the hose end and drain deposits into a suitable con...
Page 54 MAINTENANCE Check the insulator for cracks or damage, and the CENTER ELECTRODE electrodes for wear, fouling o r discoloration. Replace the plug if necessary. If the electrode is contaminated with carbon depos its, clean the electrode using a spark plug cleaner. Replace the plug if necessary.
Page 55 MAINTENANCE Be careful not to Install the plug maintenance lid. damage the tabs Close the fuel tank cap lid. and slots. NOTE: VALVE CLEARANCE • INSPECTION Inspect and adjust the valve clearance while the engine is cold (below 35"C/95"F). Remove the following: - Radiator cover (page 7-7) - Belt case cover (page 1 0-6) - Cylinder head cover (page 9-6)
Page 56 MAINTENANCE NOTE: ADJUSTMENT • Move the rocker arm to the spring side and remove • the shim. • Do nat allow the shims to fall into the crankcase. Mark a l l shims to ensure correct reassembly in their original locations. The shims can be easily removed with tweezers or a magnet.
Page 57: Oil Level Check
LEVEL upper level.._ RECOMMENDED ENGINE OIL: Pro Honda GN4 4-stroke oil (U.S.A. and Canada) or LOWER an equivalent motor oil LEVEL API service classification: SG or higher JASO T 903 standard: MA @�!#jiM...
Page 58: Oil Change
NOTE: MAINTENANCE • OIL CHANGE Change the oil with the engine warm and the scooter placed on its center stand to assure com� plete and rapid draining. Warm up the engine to normal operating tempera- ture. Stop the engine and remove the oil filler cap/dip stick.
Page 59: Engine Idle Speed
MAINTENANCE ENGINE OIL STRAINER SCREEN Drain the engine oil (page 4-1 1 ) . Remove t h e o i l strainer cap a n d 0-ring. Remove the spring and oil strainer screen. Clean the oil strainer screen. Coat a new D-ring with oil. Install the oil strainer screen and spring i nto the crankcase as shown.
Page 60: Cooling System
MAINTENANCE Disconnect the tachometer and install the plug maintenance lid removed parts. RADIATOR COOLANT Support the scooter with its center stand on a level surface. Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the "UPPER"...
Page 61 MAINTENANCE Remove the radiator cover (page 7-7). Check the radiator air passage for clogs or damage. Straighten bent fins with a small, flat blade screw driver and remove insects, mud or ather obstruc tions with compressed air o r low pressure water. Replace the radiator if the air flow is restricted over more than 20% of the radiating surface.
Page 62 MAINTENANCE SECONDARY AIR SU PPLY SYSTEM (After '05 model) Remove t h e floor step (page 3-7). Check the air supply hose between the air cleaner housing and PAIR check valve for damage or loose connection. If the hose shows any signs of heat damage, inspect AIR SUPPLY HOSE the PAIR check valve (page 6-23).
Page 63: Brake System
MAINTENANCE BRAKE SYSTEM Measure the brake lever free play at the end of the 1 0 - 20 mm lever. (3/8 - 13/16 in) FREE PLAY: 10 - 20 mm (3/8 - 13/16 in) Make sure the cut- Adjust the brake lever free play by turning the brake out on the ad justing arm adjusting nut.
Page 64 MAINTENANCE H EADLIGHT AIM Support t h e scooter with its center stand on a level surface Adjust the headlight Adjust the headlight aim vertically by loosening the aim as specified by headlight guard mounting bolts. local Jaws and regu- lations.
Page 65 MAINTENANCE Raise the rear wheel off the ground and support the scooter securely. Check for worn engine mounting bushings by grab bing the rear wheel and attempting to move the wheel side-to-side. Replace the bushings if any looseness is noted (page 8-4).
Page 66 MAINTENANCE Raise the wheel off the ground a n d support the scooter securely. Check for worn wheel bearings by grabbing the wheel and attempting to move the wheel side to side. Replace the bearings if any looseness is noted. Refer to front wheel bearing replacement (page 14- Refer to rear final gear shaft bearing replacement (page 1 1 -8).
Page 67 5 . LU BRICATIO N SYSTEM LUBRICATION SYSTEM DIAGRAM ············· 5-2 TROUBLESHO OTING ,5-3 ........SERVICE INFORMATION OIL PUM p .
Page 68 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM CRAN !<SHAFT ROCKER ARM SHAFT PISTON ROCKER ARM OIL STRAINER...
Page 69: Troubleshooting
E n g i n e oil capacity At draining 0.7 liter (0.7 US qt, 0.61mp qt) At disassembly Pro Honda GN4 4-stroke oil (U.S.A. and Canada) or an equivalent Recommended engine oil motor oil API service classification: SG or higher...
Page 70 LU BRICATION SYSTEM O I L PUMP pump, REMOVAL Drain the engine oil (page 4-1 1 ) . When removing Drain the coolant from the cooling system (page 7- and installing the oil do not alfow dust or dirt to enter Remove the following: the engine.
Page 71 LUBRICATION SYSTEM DISASSEMBL Remove the dowel pin, screw and oil pump cover. SCREW DOWEL PIN Remove the oil pump outer rotor and inner rotor. NOTE: OUTER ROTOR INNER ROTOR • INSPECTION Measure each clearance at several points and use the largest reading to compare the service limit.
Page 72 LUBRICATION SYSTEM Measure the side clearance using a straight edge SIDE CLEARANCE: and feeler gauge. 0.12 (0.005 in) SERVICE LIMIT: ASSEMBLY Dip all parts in clean engine oil before assembly. OIL PUMP DRIVEN GEAR OIL PUMP BODY OIL PUMP COVER DOWEL PIN INNER ROTOR SCREW...
Page 73: Lubrication System
LUBRICATION SYSTEM Install the oil pump cover onto the oil pump body. Install and tighten the oil pump cover screw to the specified torque. TORQUE: 2.0 N·m (0.2 i<gf·m, 1.4 lbf . ft) INSTALLATION I nstall the oil pump by aligning the dowel pin and screw with the grooves of the crankcase.
Page 74 LUBRICATION SYSTEM Apply engine oil to a new oil seal lip and install it into the stator base. Coat a new D-ring with oil and install it into the sta tor base. Apply engine oil to the oil pump driven gear sliding surface of the stator base.
Page 75: Table Of Contents
6. FUEL SYSTEM COMPONENT LOCATIONs PILOT SCREW ADJUSTMENT (' 0 3 - 'OS mod el ) ......6-18 .
Page 76: Component Locations
FUEL SYSTEM COMPON ENT LOCATIONS AFTER '05 MODEL:...
Page 77: Service Inf Ormation
FUEL SYSTEM • SERVICE IN FORMATION • GENERAL • • Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can • cause a fire or explosion. For fuel pump inspection, refer to page 1 9-18. •...
Page 78: Starting Enrichment {Se) Valve
FUEL SYSTEM • • TROUBLESHOOTING Engine won't start No fuel in tank No fuel to carburetor • - Clogged fuel filter - Clogged fuel hose - Clogged fuel cap breather hole • - Faulty fuel pump (page 1 9-18) • Too much fuel getting to the engine •...
Page 79: Air Cleaner Housing
FUEL SYSTEM AIR ClEANER HOUSING REMOVAL/INSTALLATION '05 model) {'03 Refer to page Remove the floor step (page 3-7). for air cleaner element Remove the rear fender bolt. replacement. Disconnect the engine breather and vacuum piston hoses from the air cleaner housing. Release the engine breather drain hose from the clamp.
Page 80: Fuel System
FUEL SYSTEM REMOVAL/INSTALLATION (After '05 model) Refer to page 4-5 for air cleaner Remove the floor step (page 3-7). element Remove the rear fender bolt. replacement. Disconnect the engine breather, air suction and vac uum piston hoses from the air cleaner housing. Release the engine breather drain hose from the clamp.
Page 81: Carburetor Removal
FUEL SYSTEM CARBURETOR REMOVAL Remove the floor step {page 3-7). THROTILE CABLE 2P CONNECTOR '05 model: Disconnect the vacuum piston hose and fuel hose � from the carbu retor. CONNECTOR Pinch the carburetor water hoses with hose clamps and disconnect the water hose. Disconnect the throttle position sensor 3P and start...
Page 82: Carburetor Disassembly
FUEL SYSTEM Loosen the connecting hose band screw and insula tor band screw. Be careful not to Remove the carburetor as an assembly. damage the insulator and connecting hose. Disconnect the water hose. Loosen the insulator band screw and remove the insulator from the intake manifold.
Page 83: Vacuum Chamber
FUEL SYSTEM STARTING ENRICHMENT (SE) VALVE Remove the SE valve cover, screw, set plate and SE COVER valve. SE VALVE Inspect the SE valve and needle for stepped wear or VALVE damage. NEEDLE VACUUM CHAMBER The vacuum Remove the screws while holding the vacuum VACUUM CHAMBER COVER chamber cover is chamber cover.
Page 84: Float Chamber
FUEL SYSTEM Be careful nat to Turn the needle holder counterclockwise while damage the pressing it in and remove it from the vacuum pis diaphragm. ton. Remove the spring and jet needle from the vacuum piston. NEEDLE HOLDER Air can leak out of Check the following: DIAPHRAGMNAC U U M PISTON the vacuum Jet needle for stepped wear...
Page 85: Seat
FUEL SYSTEM Inspect the float valve seat for scores, scratches, FLOAT VALVE clogs and damage. Check the operation of the float valve. Check the tip of the float valve where it contacts the valve seat for stepped wear or contamination. Replace the valve if the tip is warn or contaminated.
Page 86: Carburetor Assembl Y
FUEL SYSTEM CARBURETOR ASSEMBLY FLOAT VALVE FLOAT SPRING JET NEEDLE HOLDER � NEEDLE SPRING � ---- -- -- - JET NEEDLE PILOT SCREW SE VALVE COVER SET PLATE FLOAT CHAMBER Install the following: Handle the jets with NEEDLE JET care. They can Slow jet easily be scored or - Needle jet...
Page 87 NOTE: FUEL SYSTEM • FLOAT LEVEL INSPECTION Check the float level after checking the float valve, valve seat and float. Set the float level With the float valve seated and the float arm just FLOAT LEVEL GAUGE gauge so that it fs touching the valve, measure the float level using the perpendicular to the special tool as shown.
Page 88 FUEL SYSTEM Be careful not to Install the diaphragm/vacuum piston assembly into SPRING damage the jet the carburetor body. needle. Be careful not to Lift the bottom of the piston with your finger to set pinch the the diaphragm rib in the groove of the carburetor diaphragm, and body.
Page 89 FUEL SYSTEM Install the throttle position sensor (page 1 7-9). THROTTLE POSITION SENSOR CARBU RETOR INSTALLATION Coat a new D-ring with oil and i nstall it into the i ntake manifold groove. Install the intake manifold by tightening the bolts. Install the insulator by aligning the groove of the insulator with the tab of the intake manifold.
Page 90 FUEL SYSTEM Install the carburetor body between the insulator and connecting hose. Align the tab of the carburetor with the tab of the insulator. '03 - '05 model: Tighten the band screws securely. 5 ± 1 mm (0.2 ± 0.04 in) After '05 model: Tighten the band screws to the specified torque.
Page 91 FUEL SYSTEM After '05 model: Connect the throttle cable to the throttle drum and THROTTLE CABLE i nstall it to the cable holder. 2P CONNECTOR Loosely tighten the throttle cable adjusting nut. Connect the throttle position sensor 3P connector and starting enrichment (SE) valve 2P connector. Connect the fuel hose, vacuum piston hose and water hose to the carburetor.
Page 92 FUEL SYSTEM PILOT SCREW ADJ USTMENT ('03 - '05 model) • IDLE DROP PROCEDURE Remove the plug maintenance lid (page 4-6). • The pilot screw is factory pre-set and no adjust ment is necessary unless the pilot screw is replaced. Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate a 50 rpm change.
Page 93 FUEL SYSTEM P I LOT SCREW ADJ USTMENT (After '05 model) • IDLE DROP PROCEDURE Remove the plug maintenance lid (page 4-6). • The pilot screw is factory pre-set and no adjust ment is necessary unless the pilot screw is replaced.
Page 94 FUEL SYSTEM H I G H ALTITUDE ADJ USTMENT (After '05 model) When the vehicle is to be operated continuously This adjustment MAIN JET above 2,000 m (6,500 feet), the carburetor must be must be made at readjusted described below i mprove high altitude to driveability and decrease exhaust emissions.
Page 95 FUEL SYSTEM When the vehicle is to be operated continuously below 1 ,500 m (5,000 feet), readjust the carburetor as follows. Warm up the engine to operating temperature. Ride the scooter for approximately 1 0 minutes. Turn the pilot screw out 1/4 turn from the high alti tude setting.
Page 96 FUEL SYSTEM OPERATION INSPECTION Remove the following: - Carburetor (page 6-7) - Float chamber (page 6-10) Insert a vinyl hose into the starter jet (fuel enrich ment circuit) and blow into the hose. Air should flow into the circuit. Connect the 12 V battery to the SE valve 2P connec tor terminals and wait 5 minutes.
Page 97 FUEL SYSTEM Start the engine and open the throttle slightly to be certain that air is sucked in through the secondary air intake ports of the air cleaner housing. If the air is not drawn in, check the air supply hose for clogs.
Page 98 FUEL SYSTEM Remove the PAIR check valve from the valve cover. Check the reed valve for damage or fatigue. VALVE STOPPER Replace the PAIR check valve if the rubber seat is cracked, deteriorated or damaged, or if there is clearance between the reed and seat. Install the PAIR check valve into the valve cover as shown.
Page 99 FUEL SYSTEM Disconnect the PCV control solenoid valve 2P con- � nectar. Remove the bolts and PCV solenoid valve from the PCV CONTROL SOLENOID VALVE PCV reed valve case. Remove the 0-ring from the solenoid valve. BOLTS Remove the bolts and cover from the case. CASE COVER BOLTS...
Page 100 FUEL SYSTEM Install the cover to the case and tighten the bolts CASE securely. COVER BOLTS Replace the 0-ring with a new one and install it to PCV CONTROL SOLENOID VALVE the solenoid valve. Tighten the solenoid valve bolts securely. PCV CONTROL SOLENOID VALVE BOLTS Connect the PCV control solenoid valve 2P connec...
Page 101 FUEL SYSTEM Install and tighten the bolts securely. SOLENOID VALVE/STAY Connect the air suction hoses. INSPECTION Remove the PCV control solenoid valve and PCV reed valve (page 6-24). PCV CONTROL SOLENOID VALVE Check that the air should flow (AI to (B), only when the 12V battery is connected to the PCV control sole...
Page 102 FUEL SYSTEM PCV REED VALVE Check the followings: VALVE STOPPER - PCV reed valve for wear or damage - Valve seat for wear or damage - Valve stopper for damage Check the no clearance between the PCV reed valve and valve seat. Replace the PCV reed valve as an assembly, if nec...
Page 103 FUEL SYSTEM FUEL TANK FUEL RESERVE SENSOR 3P CONNECTOR FUEL HOSE FUEL FILTER 6-29...
Page 105 COOLING SYSTEM SYSTEM FLOW PATTERN RESERVE TANK WATER PUMP THERMOSTAT RADIATOR...
Page 106: Radiator Cover
COOLING SYSTEM S ERVICE I N FORMATION 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. NOTICE •...
Page 107 COOLING SYSTEM TRO U BLESHOOTING • Engine temperature too high • Thermostat stuck closed • • Faulty radiator cap • Insufficient coolant • Passage blocked in radiator, hoses or water jacket • Air in system Faulty water pump • Faulty ECT sensor Engine temperature too low •...
Page 108 COOLING SYSTEM COOLANT SYSTEM TESTING COOLANT (HYDROMETER TEST) Remove the four screws and radiator cover. Remove the radiator cap. Pinch the siphon hose with a hose clamp. Test the coolant gravity using a hydrometer (see below for "Coolant specific gravity chart"). For maximum corrosion protection, a 1 : 1 solution of ethylene glycol and distilled water is recommended (page 7-6).
Page 109: Coolant Replacement
Mix only distilled, low mineral water with the rec- om mended antifreeze. ANTIFREEZE RECOMMENDED ANTIFREEZE: SOLUTION Pro Honda HP Coolant or an equivalent high qual ity ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended (ETHYLENE for use in aluminum engines...
Page 110 NOTE: COOLING SYSTEM • REPLACEMENT AIR BLEEDING When filling the system or reserve tank with coolant, or checking the coolant level, place the scooter on its center stand on a flat, level surface. Remove the four screws and radiator cover. Remove the radiator cap.
Page 111 COOLING SYSTEM Support the scooter with its center stand on a level surface. Fill the reserve tank with the recommended coolant to the upper level line. Fill the system with the recommended coolant through the filler opening to the filler neck. Bleed air from the system as follow: 1.
Page 112 COOLING SYSTEM Remove the wire band from the water pump stay. Disconnect the water hoses. Remove the bolts and water pump. Remove the D-ring from the water pump. THERMOSTAT Remove the bolts, stay and thermostat cover. STAY COVER Remove the rubber seal from the thermostat cover. RUBBER SEAL Remove the thermostat.
Page 113 COOLING SYSTEM THERMOSTAT INSPECTION Visually inspect the thermostat for damage. Heat a pan of water with an electric heating element Keep flammable to operating temperature for 5 minutes. materials away Suspend the thermostat in the heated water to from the electric check its operation.
Page 114 COOLING SYSTEM ..I nstall a new rubber seal i nto the thermostat cover RUBBER SEAL groove. !$.! , I nstall the thermostat housing cover, stay and BOLTS STAY tighten the bolts securely. COVER WATER PUMP Clean the inside of the outer magnet and the water pump magnet, and check that no nuts or bolts are magnetically attached to the magnet.
Page 115 COOLING SYSTEM Connect the water hoses. Install the wire band onto the stay. Connect the water hoses. Install the following: - Ignition coil (page 17-7) - Floor step (page 3-7) Fill and bleed the cooling system (page 7-8). RADIATOR REMOVAL Drain the coolant from the cooling system (page 7- Disconnect the siphon hose and water hoses from the radiator.
Page 116 COOLING SYSTEM Remove the water pipe and 0-rings. INSTALLATION WATER HOSE SIPHON HOSE 0-RINGS WATER HOSE RADIATOR Coat the new 0-rings with coolant and install them ll"'��" "" ""' ''l i nto the grooves of the water pipe. Install the water pipe and align the guide of the crankcase with the water pipe as shown.
Page 117 COOLING SYSTEM Install the radiator onto the crankcase, aligning the water pipe with the pipe joint of the radiator. Tighten the radiator and rear fender mounting bolts securely. Connect the siphon hose and water hoses. Fill and bleed the cooling system (page 7-B). RADIATOR RESERVE TANK REMOVAL/INSTALLATION Drain the coolant from the radiator reserve tank...
Page 118 COOLING SYSTEM Disconnect the siphon hose from the reserve tank and remove the bolt. Remove the radiator reserve tank by releasing its grommet from the frame stay. Installation is in the reverse order of removal. 7- 1 5...
Page 119 8 . E N G I N E REM OVAL/INSTALLATION COMPONENT LOCATIONS ······· ....8-2 ENGINE REMOVAL ························· ···············8-4 SERVICE INFORMAT ION ······················ ········ 8-3 ENGINE INSTALLATIO N ·················· ··············8-7...
Page 120 ENGINE REMOVAL/INSTALLATION COMPO NENT LOCATIONS 39 N·m (4.0 kgf·m, 29 lbf.ft) 38 N·m (3.9 kgf·m, 28 lbf.ft) 49 N·m (5.0 kgf·m, 36 lbf.ft)
Page 121 ENGINE REMOVAL/INSTALLATION • SERVICE I NFORMATION • • GENERAL • During engine removal and installation, support the scooter using a hoist or equivalent. • Support the engine using a jack or other adjustable support to ease of engine mounting bolt removal. When removing/installing the engine, tape the frame around the engine beforehand .for frame protection.
Page 122: Engine Removal
ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Remove the floor step (page 3-7). Drain the engine oil (page 4-11 ). Drain the coolant from the cooling system (page 7- NOTICE Install the radiator cover to prevent the radiator fin from damage. Remove the bolts, clamps and ground wire. Remove the rear brake arm adjusting nut, joint pin and spring.
Page 123 ENGINE REMOVAL/INSTALLATION Disconnect the siphon hose, fuel hose and th rottle cable. Disconnect the engine breather hose and ignition coil wire connectors. Pull out the air supply hose from the inner side of AIR SUPPLY HOSE the under cover. Place a floor jack or other adjustable support under the frame.
Page 124 ENGINE REMOVAL/INSTALLATION After '05 model Disconnect the air suction hoses from the PCV con- � only: trol solenoid valve. Remove the engine mounting nut. Pull out the engine mounting bolt, then remove the engine from the frame. Move the joint tubes inside and remove the mount ing collar from the engine.
Page 125: Engine Installation
ENGINE REMOVAL/INSTALLATION Check the rubber stopper and bushings for damage, wear or deterioration. NOTE: • ENGINE INSTALLATION • Before installing the engine, route the wires, hoses and cables properly (page 1 - 1 5). The jack height must be continually adjusted to relieve stress from the mounting fasteners.
Page 126 ENGINE REMOVAL/INSTALLATION Set the engine to the frame and install the engine mounting bolt from the left side. Tighten the engine mounting nut to the specified torque. TORQUE: 49 N·m (5.0 kgf·m, 36 lbf·ft) Tighten the rear shock absorber upper mounting bolt to the specified torque.
Page 127 9. CYLI NDER HEAD/VALVE S CYLINDER HEAD DISASSEMBLY ···············9 - 11 COMPONENT LOCATIONS ·· ......9-2 VALVE GUIDE REPLACEMENT ....9 . 13 SERVICE INF ORMATION ······················ ········ 9-3 VALVE SEAT INS PECTION/REFACING ······9 - 14 TROUBLESHOO TING ··················...
Page 128: Component Locations
CYLINDER HEAD/VALVES COMPONENT LOCATIONS 1 0 N·m ( 1 .0 kgf·m, 7 1bf.ft) AFTER '05 MODEL: 12 N·m ( 1 .2 kgf·m, 9 1bf.ft) • , _ _ _ _ _ ......
Page 129 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 130 CYLINDER HEAD/VALVES TOOLS Seat cutter, 20.5 mm (45" I N ) Seat cutter, 1 7 mm (45" EX) Valve spring compressor 07780-0011000 07780-0011100 07757-0010000 or equivalent commercially avail or equivalent commercially avail able in U.S.A. able in U.S.A. Flat cutter, 22 mm (32" IN) Flat cutter, 20 mm (32"...
Page 131 • CYLINDER HEAD/VALVES • TROU BLESHOOTING Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test or by tracing engine noises to the top-end with a sounding rod or stethoscope. • If the performance is poor at low speeds, check for white smoke in the engine breather drain hose. If the hose is smoky, check for a seized piston ring (page 1 3-8).
Page 132 CYLINDER HEAD/VALVES CYLI NDER COMPRESSION TEST Warm up the engine to normal operating tempera ture. Stop the engine and remove the spark plug cap and spark plug (page 4-6). Connect a compression gauge to the spark plug hole. T o avoid discharging Open the throttle all the way and crank the engine the battery.
Page 133 CYLINDER HEAD/VALVES CAMSHAFT /ROCKER ARMS REMOVAL Remove the following: - Belt case cover (page 1 0-6) - Water pump (page 7-8) - Cylinder head cover (page 9-6) Rotate the drive pulley (crankshaft) counterclock wise and align the index line on the cam sprocket with the index mark on the stopper plate.
Page 134 CYLINDER HEAD/VALVES Remove the two bolts and outer magnet while hold- ing the crankshaft. Remove the cam sprocket from the camshaft and cam chain from the cam sprocket. Attach a piece of wire to the cam chain to prevent it from falling into the crankcase.
Page 135 CYLINDER HEAD/VALVES INSPECTION CAMSHAFT Check the camshaft bearing for wear or damage. Turn the bearing outer race with your finger. The bearings should turn smoothly and quietly. Also check that the bearing inner race fits tightly on the camshaft. Replace the camshaft assembly if the race does not turn smoothly and quietly, or if it fits loosely on the camshaft.
Page 136 CYLINDER HEAD/VALVES CAM CHAIN TENSIONER LIFTER Remove the two bolts and tensioner lifter (page 9- TENSIONER SHAFT Check the lifter operation: - The tensioner shaft should not go into the body when it is pushed. - When it is turned clockwise with a screwdriver, the tensioner shaft should be pulled i nto the body.
Page 137: Cylinder Head Disassembly
CYLINDER HEAD/VALVES Remove the gasket and dowel pins. D-RING Remove the 0-ring from the i ntake manifold groove. GASKET CYLINDER HEAD DISASSEMBLY Remove the spark plug and ECT sensor from the cylinder head. SPARK PLUG Remove the valve spring cotters using the special T o prevent loss of tools.
Page 138 CYLINDER HEAD/VALVES Avoid damaging the Remove the carbon deposits from the combustion mating and valve chamber and clean off the head gasket surface. seat surfaces. INSPECTION CYLINDER HEAD Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a straight edge and feeler gauge.
Page 139 CYLINDER HEAD/VALVES Ream the valve guide to remove any carbon build REAMER up before measuring the guide. Insert the reamer from the combustion chamber side of the head and always rotate the reamer clock- wise. TOOL: Valve guide reamer, 4.508 mm 07HMH-ML00101 or 07HMH-ML0010B o r 07HMH-ML0010A {U.S.A.
Page 140 CYLINDER HEAD/VALVES Drive the new guides into the cylinder head from the camshaft side while the cylinder head is still heated. TOOL: Valve guide driver, 4.5 mm 07HMD-ML00101 VALVE GUIDE PROJECTION: IN/EX: 9.05 - 9.35 mm (0.356 - 0.368 in) Let the cylinder head cool to room temperature.
Page 141 • CYLINDER HEAD/VALVES • I nspect the valve seat face for: Damaged face: - Replace the valve and reface the valve seat Uneven seat width: - Bent or collapsed valve stem; Replace the valve and reface the valve seat • DAMAGED FACE U N EVEN SEAT WIDTH Contact area (too low or too high area):...
Page 142 CYLINDER HEAD/VALVES Use a 45° seat cutter, remove any roughness or irregularities from the seat. Re face the se at TO OL S: with a 45°c utter Seat cutte r, 20.5 mm {45° IN) 07780-0011000 wheneve r a valve Seat cutter, 17 mm (45° EX) 07780-0011100 07781-0010600 or Cutter holder, 4.5 mm...
Page 143 CYLINDER HEAD/VALVES Excessive lapping After cutting the seat, apply lapping compound to LAPPING TOOL pressure mav the valve face, and lap the valve using light pres deform or damage sure. the seat, Change the angle of the lapping tool frequently to Do not allow lap- prevent uneven seat wear, After lapping, wash any residual compound off the ping compound to...
Page 144 CYLINDER HEAD/VALVES Install the valve springs with the tightly wound coils facing the combustion chamber. Install the spring retainers. COMBUSTION CHAMBER __..lAAMNI Grease the cotters Install the valve spring cotters using the special to ease installation. tools. TOOLS: T o prevent loss of Valve spring compressor 07757-0010000...
Page 145 CYLINDER HEAD/VALVES Route the cam chain through the cylinder head and install the cylinder head onto the cylinder. Loosely install the cylinder head mounting bolts. Install the intake manifold joint bolts and tighten them securely. Connect the vacuum hose and water hose. Install a n d tighten the spark plug to the specified torque.
Page 146 CYLINDER HEAD/VALVES Install the rocker a rms and side springs as shown. Coat a new D-ring with oil. Install the intake Apply engine oil to the sliding surfaces of the rocker shaft with the cut- arm shafts and install it with a new 0-ring to the cyl out facing outside.
Page 147 CYLINDER HEAD/VALVES Apply engine oil to the cam sprocket bolt threads and seating suriaces. Apply engine oil to the cam sprocket gear teeth. Clean the inside of the outer magnet and check that no nuts or bolts are attached to the magnet. Install the outer magnet and bolts.
Page 148 CYLINDER HEAD/VALVES Remove the special tool to cancel the lock of the After 05 model: tensioner l ifter. Coat new 0-rings with oil. Install new 0-rings to the PCV joint and cam chain tensioner l ifter groove. Install the PCV joint to the cam chain tensioner. After '05 model: Install the bolt and washer.
Page 149: Troubleshoo Ting
1 0. KICKSTARTER/DRIVE PU LLEY/DRIVEN PU LLEY/CLUTCH COMPONENT LOCATIONs ......10 -2 KICKSTARTER ..........10 -6 SERVICE INFORMATION ············ ················ 1 0 -3 DRIVE PULLEY ··············································10 -9 TROUBLESHOO TING ........10 -5 CLUTCH/DRIVEN PULLEY ··········· ··············1 0 -1 2 BELT CASE COVER ························...
Page 150 KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH COMPONENT LOCATIONS 32 N·m (3.3 kgf·m, 24 1bf.ft) 39 N·m (4.0 kgf·m, 29 lbf.ft) 1 0-2...
Page 151 KICKSTARTER/DRIVE PULLEY /DRIVEN PULLEY /CLUTCH • S ERVICE INFORMATION • • GENERAL • This section covers maintenance of the kickstarter, drive pulley, driven pulley and clutch. These services can be done with the engine installed in the frame. Avoid getting grease and oil on the V-belt and pulley drive faces in order to prevent belt slippage. Do not apply grease to the movable drive face and weight rollers.
Page 152 KICKSTARTER/DRIVE PULLEY /DRIVEN PULLEY /CLUTCH TOOLS Universal holder Remover weight Attachment, 22 x 24 mm 07725-0030000 07741-0010201 07746-0010800 or 07936-371020A or 07936-3710200 (U.S.A. only) Pilot, 17 mm Driver Pilot, 12 mm 07746-0040200 07746-0040400 07749-0010000 Remover handle Bearing remover, 17 mm Snap ring pliers 07914-SA50001 07936-3710100...
Page 153 KICKSTARTER/DRIVE PULLEY /DRIVEN PULLEY /CLUTCH • • TROU BLESHOOTING • • Engine starts but scooter won't move Worn drive belt Damaged ramp plate Worn or damaged clutch shoe • Broken driven face spring • Engine stalls or scooter creeps Broken clutch shoe spring •...
Page 154 KICKSTARTER/DRIVE PULLEY /DRIVEN PULLEY /CLUTCH B ELT CASE COVER REMOVAL Remove the air cleaner housing bolt. Remove the bolts, clamp and belt case cover. Remove the rubber seal and dowel pins from the RUBBER SEAL belt case cover. INSTALLATION Check the rubber seal and replace it if necessary. Clean the rubber seal groove of the belt case cover.
Page 155 KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH When Remove the bolt a n d kickstarter pedal. disassembling the kickstarter, mark the pedal position to ensure correct reassemblv in its original location. Release the hook end of the return spring from the belt case cover stopper. Remove the snap ring and washer.
Page 156 KICKSTARTER/DRIVE PULLEY /DRIVEN PULLEY /CLUTCH Check the journals of the belt case cover for wear or damage. ASSEMBLY KICKSTARTER PEDAL WASHER COLLAR SNAP RING RETURN SPRING STARTER DRIVEN GEAR KICKSTARTER SPINDLE Install the spindle bushing and collar onto the belt GROOVE case cover.
Page 157 KICKSTARTER/DRIVE PULLEY /DRIVEN PULLEY /CLUTCH Install the thrust washer and snap ring in the groove of the spindle. Hook the return spring end onto the stopper on the belt case cover. Install the kickstarter pedal to its original position as marked during removal.
Page 158 KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Remove the movable drive face assembly while holding the back of the ramp plate. Remove the drive face boss from the movable drive face assembly. Remove the ramp plate and weight rollers. RAMP PLATE WEIGHT ROLLER INSPECTION DRIVE BELT Check the d rive belt for cracks, separation, abnor...
Page 159 KICKSTARTER/DRIVE PULLEY /DRIVEN PULLEY /CLUTCH MOVABLE DRIVE FACE Check the d rive face boss far wear or damage. Measure the boss O.D. SERVICE LIMIT: 19.97 mm (0.786 in) Measure the face bushing I. D. SERVICE LIMIT: 20.13 mm (0.793 in) ASSEMBLY Clean any oil and grease from the pulley faces and weight rollers.
Page 160 KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH CLUTCH/DRIVEN PULLEY REMOVAL Remove the drive pulley (page 10-9). Hold the clutch outer with the special tool a n d loosen the clutch outer nut. TOOL: Universal holder 07725-0030000 Remove the nut a n d clutch outer. Remove the clutch/driven pulley assembly.
Page 161 KICKSTARTER/DRIVE PULLEY /DRIVEN PULLEY /CLUTCH Install the gear puller or equivalent tool and special GEAR PULLER tool as shown. TOOL: Puller attachment 07YMC-GCS0100 Loosen the clutch spring compressor gradually and tighten the gear puller gradually. Repeat this procedure and remove the clutch assembly from the driven face.
Page 162 KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH 1.0. INSPECTION CLUTCH OUTER Check the clutch outer for wear or damage. Measure the clutch outer SERVICE LIMIT: 107.5 mm (4.23 in) CLUTCH SHOE LINING Check the clutch shoe for wear or damage. Measure the thickness of each shoe. SERVICE LIMIT: 2.0 mm (0.08 in) DRIVEN FACE SPRING Measure the driven face spring free length.
Page 163 KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH DRIVEN FACE BEARING REPLACEMENT Remove the snap ring using the special tool. TOOL: Snap ring pliers 07914-SA50001 Remove the driven face needle bearing_ using the special tools. TOOL: Bearing remover, 17 mm 07936-3710300 Remover handle 07936-3710100 Remover weight 07741-0010201or 07936-371020A or 07936-3710200...
Page 164 KICKSTARTER/DRIVE PULLEY /DRIVEN PULLEY /CLUTCH Apply grease to a new needle bearing. Press the needle bearing into the driven face with the marked side facing up. DRIVER ATTACHMENT TOOLS: Driver 07749-0010000 Attachment, 22 X 24 mm 07746-0010800 PILOT Pilot, 17 mm 07746-0040400 Install the snap ring to the groove of the driven face securely.
Page 165 KICKSTARTER/DRIVE PULLEY /DRIVEN PULLEY /CLUTCH Install the shoe springs into the clutch shoes as LONG shown. SHORT SHORT SPRING Install the clutch shoes assembly into the drive SHOES plate. Install the washers and E-clips. SPRING E-CLJPS/WASHERS Assemble the movable driven face, spring seat and MOVERABLE DRIVEN FACE driven face.
Page 166 KICKSTARTER/DRIVE PULLEY /DRIVEN PULLEY /CLUTCH Set the clutch spring compressor over the clutch/ To prevent loss of driven pulley assembly and compress the driven tension, do not face spring. compress the clutch spring more TOOL: than necessary to 07LME-GZ40200 or Clutch spring compressor install the stopper 07960-KM1000A...
Page 167: Table Of Contents
1 1 . FI NAL REDUCTIO N COMPONENT LOCATIONs ......11-2 SERVICE INFORMATION · · · · · · · · · · · · · · · · · ··········· 11-3 BEARING REPLACEMENT ······················ ····· 11-8 TROUBLESHOOTI NG ········ ·························· 11-4 FINAL REDUCTION OIL ··············...
Page 168 FINAL REDUCTION COMPONENT LOCATIONS 12 7 kgf·m, 20 lbf.ft) ·m · 1 1 -2...
Page 169: Final Reduction
FINAL REDUCTION • SERVICE I N FORMATION • • GENERAL This section covers m aintenance of the final reduction. These services can be done with the engine installed in the frame. When installing the drive s haft, be sure to use the special tool; position the special tool a g ainst the bearing inner race and pull the drive shaft i nto the bearing.
Page 170 FINAL REDUCTION Universal bearing puller Bearing remover set, 12 mm Bearing remover head, 12 mm 07931-4630000 07936-1660101 07936-1660110 not available in U.S.A. not available in U.S.A. or equivalent commercially avail or Bearing remover, 12 mm able in U.S.A. 07936-166010A (U.S.A. only) Bearing remover shaft Assembly collar Assembly shaft...
Page 171: Final Reduction Oil
FINAL REDUCTION FINAL REDUCTION OIL LEVEL CHECK Make sure the final reduction case has no oil leaks. Support the scooter with its center stand on a level surface. Warm up the engine to normal operating tempera ture. Remove the final reduction oil check bolt and check whether the oil flows out from the check bolt hole.
Page 172 FINAL REDUCTION Remove the seven bolts and hose clamp. Remove the transmission case and drain all oil to the suitable container from the transmission case. Remove the dowel pins. Clean any sealant from the transmission case mat ing su rface. Remove the thrust washers and countershaft.
Page 173 FINAL REDUCTION If the bearing is left on the drive shaft, remove it using the special tool. BEARING PULLER TOOL: 07931-4630000 or Universal bearing puller equivalent commercially available in U.S.A. INSPECTION Remove the oil seal. DRIVE SHAFT BEARING Turn the inner race of each bearing with your finger. The bearings should turn smoothly a n d quietly.
Page 174 FINAL REDUCTION B EARING REPLACEMENT DRIVE SHAFT DRIVE SHAFT BEARING (6203) FINAL GEAR SHAFT BEARING (6203UU) OIL SEAL FINAL GEAR SHAFT OIL SEAL Be careful not to Remove the final gear shaft oil seal and bearing. damage the trans- mission case mat- ing surface.
Page 175 FINAL REDUCTION Remove the drive shaft bearing using the special tools. TOOLS: Bearing remover set, 12 mm 07936-1660101 not available in U.S.A. - Bearing remover head, 12 mm 07936-1 660110 not available in U.S.A. - Bearing remover shaft 07936-1660120 not available in U.S.A.
Page 176 FINAL REDUCTION Install the drive shaft into the belt case. Position the assembly collar against the d riveshaft bearing inner race. Thread the assembly shaft onto the driveshaft. Hold the assembly shaft a n d draw the driveshaft into the bearing inner race by turning the nut. TOOLS: Assembly shaft 07965-GM00300...
Page 177 FINAL REDUCTION Install the countershaft i nto the transmission case. COUNTER SHAFT Install the thrust washers onto the countershaft and final gear shaft. Apply sealant to the transmission case mating sur face as shown. Install the dowel pins. Apply molybdenum grease 0.5 - 1 .0 gram to the countershaft sliding surface.
Page 178 FINAL REDUCTION Install the clamp, bolts and tighten them i n a criss cross pattern in two or three steps. Install the air cleaner housing and tighten the bolt securely. Install the engine breather drain hose into the clamp. Install the brake cable through the cable holder. Install the following: - Rear brake (page 1 5-6) - Rear wheel (page 1 5-4)
Page 180 ALTERNATOR/STARTER COMPONENT LOCATIONS 1 2 N·m ( 1 .2 1cgf·m, 9 lbf . ft) N·m (4.5 kgf·m, 33 lbf . ft) 7.8 N·m (0.8 kgf·m, 5.8 lbf . ft) 1 2-2...
Page 181 ALTERNATOR/STARTER • SERVICE I N FORMATION • GENERAL • Always turn the ignition switch to "OFP' before servicing the alternator/starter. The a lternator/starter could suddenly • start when the ignition switch is turned to "ON", causing serious injury. This section covers the removal and installation of the flywheel, alternator/starter and ignition pulse generator. These services can be done with the engine installed i n the frame.
Page 182 ALTERNATOR/STARTER ALTERNATOR/STARTER REMOVAL Remove the following: - Floor step (page 3-7) - Radiator (page 7-12) Remove the three bolts and cooling fan. Hold the flywheel with the special tool and loosen the flywheel nut. TOOL: Universal holder 07725-0030000 Remove the flywheel nut and washer. Remove the flywheel using the special tool.
Page 183 ALTERNATOR/STARTER Remove the wire band from the water pump stay. Remove the grommet from the crankcase groove. Remove the two bolts, clamp a n d ignition pulse generator. Remove the three bolts and stator. Remove the woodruff key from the crankshaft. INSTALLATION Clean any oil from the tapered portion of the crank...
Page 184 ALTERNATOR/STARTER Clean any oil from the tapered portion of the fly wheei i.D. Install the flywheel onto the crankshaft, aligning the key way with the woodruff key. NOTICE Before installing the flywheel, check that no nuts or bolts are magnetically attached to the flywheel. Install the washer and flywheel nut.
Page 185 1 3 . CRAN KSHAFT/PI STO N/CYLINDER COMPONENT LOCATIONs ......13-2 CRANKCAS E SEPARATION ························ ·13-5 SERVICE INFORMATION ···························· 13-3 CRANKSHAF T /PISTON ···················· ···· ········13-5 TROUBLESHOO TING ················ ·················· 13-4 CRANKCAS E ASSEMBLY ······················· ···13-11 1 3- 1...
Page 186 CRANKSHAFT /PISTON/CYLINDER COMPONENT LOCATIONS .2 kgf·m, 9 lbf.ft) 12 N·m 1 3-2...
Page 187 CRANKSHAFT /PISTON/CYLINDER • SERVICE INFORMATION • GENERAL This section covers the crankcase separation to service the crankshaft, piston and cylinder. The following parts must be removed before separating the crankcase. - Oil pump (page 5-4) - Water pump (page 7-8) - Carburetor (page 6-7) - Engine (page 8-4) •...
Page 188: Troubleshooti Ng
CRANKSHAFT /PISTON/CYLINDER • • TROUBLESHOOTI NG • Compression too low, hard starting or poor performance at low speed Worn, stuck or broken piston ring Worn or damaged cylinder and piston • Cylinder head/valve problem (page 9-3) • Compression too high, overheating or knocking Excessive carbon build-up on piston head or on combustion chamber •...
Page 189 CRANKSHAFT /PISTON/CYLINDER CRAN KCASE SEPARATION Remove the engine from the frame (page 8-4). Remove the following: - Cylinder head/cam chain (page 9-10) - Oil pump (page 5-41 - Drive pulley (page 10-9) Remove the four bolts and belt case. Remove the rubber seal. Remove the four bolts and center stand from the crankcase.
Page 190: Piston Removal
CRANKSHAFT /PISTON/CYLINDER PISTON REMOVAL Remove the piston pin clips with pliers. Remove the piston pin out of the piston. PISTON PISTON PIN Do not damage the Spread each piston ring and remove them by lifting piston ring by up at a point opposite the gap. spreading the ends too far.
Page 191 CRANKSHAFT /PISTON/CYLINDER Set the crankshaft on V-blocks and read the runout points as shown, using a dial indicator. Actual run out is 1/2 of total indicator reading. SERVICE LIMIT: 0.05 (0.002 in) Turn the outer race of the crankshaft bearings with your finger.
Page 192 CRANKSHAFT /PISTON/CYLINDER PISTON/CYLINDER INSPECTION Inspect the piston rings for movement by rotating the rings. The rings should be able to move in their grooves without catching. Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring-to-groove clearance.
Page 193 CRANKSHAFT /PISTON/CYLINDER Measure the piston O.D. at the point 1 0 mm (0.39 in) from the bottom of skirt and 90° to the piston pin hole. SERVICE LIMIT: 37.72 mm (1.485 in) Calculate the cylinder-to-piston clearance {cylinder I.D.: see below). SERVICE LIMIT: 0.08 mm (0.003 in) Inspect the cylinder bore for wear or damage.
Page 194: Piston Installation
CRANKSHAFT /PISTON/CYLINDER PISTON INSTALLATION Be careful not to Coat the piston and each piston ring with oil. MARK Carefully install the piston rings into the piston ring damage the piston • grooves with their markings facing up and rings. • NOTE: Do not confuse the top and second rings.
Page 195 Apply engine ail to the connecting rod big end bear ing (3 cm3), crankshaft main journal bearings (2 cm3 each), cylinder wall, piston and piston ring outer surface. Install the piston with the " I N " mark facing the intake side while compressing the piston rings with your fingers.
Page 196 CRANKSHAFT /PISTON/CYLINDER Apply engine oil to the crankcase bolt threads and seating surfaces. Install the bolts and tighten them in a crisscross pat tern in two or three steps. TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft) Install a new sealing washer and drain bolt. Tighten the drain bolt to the specified torque.
Page 197 1 4. FRONT WHEEL/BRAKE/SUSPENSION/STEERI NG 1 4-2 14-1 1 COM PON ENT LOC ATIO Ns FRONT BRAKE ......
Page 198 FRONT WHEEl/BRAKE/SUSPENSION/STEERING COMPONENT LOCATIONS 42 N·m (4.3 kgf·m, 31 lbf . ft) N·m (4.5 kgf·m, 33 lbf . ft) 1 4-2...
Page 199 When servicing the front wheel, fork or steering stem, support the motorcycle using a safety stand or hoist. Use only tires marked "TUBELESS" and tubeless valve stems on rims marked "TUBELESS TIRE APPLICABLE". Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. SPECIFICATIONS Unit"...
Page 200 FRONT WHEEL/BRAKE/SUSPENSION/STEERING TOOLS Remover weight Pilot, 1 0 mm Bearing remover shaft 07746-0040100 07746-0050100 07741-0010201 not available in U.S.A Bearing remover head, 10 mm Driver Socket wrench, 32 mm 07749-0010000 07916-KM10000 07746-0050200 1 4-4...
Page 201 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Attachment, 28 x 30 m m Fork seal driver, 27 mm Adjustable bearing remover set 07946-1870100 07947-1180001 07 JAC-PH80000 not available in U.S.A Remover head Remover shaft Lock nut wrench, 45 x 54 mm 07JAC-PH80100 07JAC-PH80200 07SMA-GBC0100 <l>/ __ ,,._,.__,"...
Page 202 FRONT WHEEL/BRAKE/SUSPENSION/STEERING • • TROUBLESHOOTI N G • • Hard steering • Steering top cone race too tight Fau lty steering head bearing Bent steering stem • Insufficient tire pressure • Faulty tire • • Steers to one side or does not track straight •...
Page 203: Front Wheel
FRONT WHEEL/BRAKE/SUSPENSION/STEERING FRONT WHEEL REMOVAL Remove the adjusting nut and brake cable from the joint pin and cable holder. Remove the joint pin from the brake arm. Disconnect the speedometer cable from the brake panel by pushing the cable tab. Remove the 0-ring from the speedometer cable.
Page 204 FRONT WHEEL/BRAKE/SUSPENSION/STEERING WHEEL Check the rim runout by placing the wheel in a turn- ,--- -- -- -- -- -- -- -- -- -, ing stand. Spin the wheel slowly and read the runout using a dial i ndicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial:...
Page 205 FRONT WHEEL/BRAKE/SUSPENSION/STEERING ASSEMBLY DISTANCE COLLAR BEARING (6200U) BEARING (6200U) Pack the new bearing cavities with grease. Drive a new left bearing (brake drum side) squarely with the sealed side facing up until it is fully seated. Install the distance collar. Drive a new right bearing squarely with the sealed side facing up until it is fully seated using the spe...
Page 206 FRONT WHEEl/BRAKE/SUSPENSION/STEERING INSTAllATION Install the brake panel aligning the tabs of the BRAKE PANEL speedometer gear with the grooves of the wheel hub. Install the front wheel between the fork legs align- ing the brake panel g roove with the left fork leg tab. Install the collar and front axle from the left side.
Page 207: Front Brake
FRONT WHEEL/BRAKE/SUSPENSION/STEERING FRONT BRAKE REMOVAL 1.0. Remove the brake panel from the front wheel (page 1 4-7). INSPECTION Measure the front brake drum SERVICE LIMIT: 95.5 mm (3.76 in) Measure the brake lining thickness. SERVICE LIMIT: 1.0 mm (0.04 in) NOTE: •...
Page 208 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Remove the dust seal and speedometer gear. DUST SEAL Remove the nut, bolt and brake arm. BRAKE ARM BOLT Remove the wear indicator plate , felt seal and return spring. Remove the brake cam from the brake panel. 1 4- 1 2...
Page 209 FRONT WHEEL/BRAKE/SUSPENSION/STEERING ASSEMBLY FELT SEAL SPEEDOMETER GEAR DUST SEAL SHOES RETURN SPRING BRAKE ARM Apply grease to the brake cam. Install the brake cam into the brake panel. Apply oil to the felt seal and install it to the brake cam.
Page 210 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the brake arm by aligning the punch marks BRAKE ARM on the brake arm and brake cam. Install the brake arm pinch bolt and nut as shown and tighten the nut to the specified torque. TORQUE: 5.4 N·m (0.55 kgf·m, 4.0 lbf . ft) Align BOLT Apply grease to the speedometer gear and pinion...
Page 211 FRONT WHEEL/BRAKE/SUSPENSION/STEERING FORK REMOVAL Remove the front wheel (page 1 4-7). Remove the upper fork pinch bolt. Loosen the lower fork pinch bolt and remove the fork tube from the steering stem. DISASSEMBL Remove the fork cap and dust seal. Clean the grease within the bottom case.
Page 212 FRONT WHEEL/BRAKE/SUSPENSION/STEERING FORK SPRING RUBBER STOPPER (RIGHT SIDE ONLY) INSPECTION l ' ' " ' " " " Check the fork tube, rubber stopper and guide bush RUBBER STOPPER (RIGHT SIDE ONLY) ing for excessive or abnormal wear. � Check the rebound spring and fork spring for fatigue or damage.
Page 213 FRONT WHEEL/BRAKE/SUSPENSION/STEERING ASSEMBLY FORK SPRING BOTTOM CASE � DUST SEAL � FORK CAP SNAP RING DUST SEAL REBOUND SPRING FORK TUBE Apply 6.5 - 8 gram of grease to the following parts. RUBBER STOPPER (RIGHT SIDE ONLY) - rebound spring - guide bushing inner su rface - fork spring tightly wound end �...
Page 214 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the rebound spring and guide bushing to the G U IDE BUSHING fork tube. Install the fork tube into the bottom case. FORK TUBE REBOUND Press the fork tube into the bottom case u ntil the SNAP RING snap ring groove is visible.
Page 215 FRONT WHEEL/BRAKE/SUSPENSION/STEERING HANDLEBAR REMOVAL Remove the speedometer (page 19-1 1 ). CONNECTORS Disconnect the connectors and remove the turn sig- nal indicator (page 1 9-10). Disconnect the front and rear brake light switch con nectors. Disconnect the right and left handlebar switch 9P and 2P connectors.
Page 216 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Disconnect the throttle cable from the throttle pipe. Remove the throttle cable from the lower housing. Loosen the rear brake adjusting nut. Remove the dust cover. Remove the rear brake lever pivot nut and screw. Disconnect the brake cable from the brake lever and remove the lever.
Page 217 Install the nut cap. CAP/NUT If the handlebar grips were removed, apply Honda Bond A or Honda Hand Grip Cement (U.S.A. only) to the inside of the grip and to the clean surfaces of the throttle pipe and left handlebar.
Page 218 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Connect the brake cable to the rear brake lever. Apply grease to the brake lever pivot screw sliding surface. Install the rear bral<e lever by tightening the pivot screw and nut. Install the throttle cable to the lower housing. Lightly tighten the th rottle cable lock nut.
Page 219: Steering Stem
FRONT WHEEL/BRAKE/SUSPENSION/STEERING Apply grease to the pivot screw sliding surface. PIVOT NUT/SCREW Connect the brake cable to the front brake lever. Install the brake lever by tightening the pivot screw and nut. Install the dust cover. Tighten the brake cable lock nut securely. Route the wires I nstall the wire bands.
Page 220: Bearing Replacement
FRONT WHEEL/BRAKE/SUSPENSION/STEERING Remove the steering stem lock nut using the special tool. TOOL: Socket wrench, 32 mm 07916-KM10000 Remove the lock washer. Loosen the top cone race using the special tool. TOOL: lock nut wrench, 45 X 54 mm 07SMA-GBC0100 Hold the steering stem and remove the steering top cone race.
Page 221 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install a new lower bearing outer race using the spe cial tools as shown. TOOLS: Stem race installer, 29 X mm 07XMF-GEE0200 (two required) not available in U.S.A. 07VMF-KZ30200 Installer shaft Install a new upper bearing outer race using the special tools as shown.
Page 222 FRONT WHEEL/BRAKE/SUSPENSION/STEERING INSTALLATION STEM COVER LOCK NUT LOCI< WASHER TOP CONE RACE � UPPER BEARING UPPER OUTER RA •" STEERI N G STEM Fill up each new bearing and inner race with grease 3 - 5 gram. Install the lower bearing onto the stem. Insert the steering stem into the steering head pipe.
Page 223 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Turn the steering stem lock-to-lack several times to seat the bearing. Temporarily loosen the steering stem top cone race. Tighten the top cone race fully by hand, after loos ening the top cone race 45°. Install the lock washer and lock nut. LOCI<...
Page 224: Table Of Contents
1 5. REAR WH EEL/BRA KE/SUSPE N SION SERVICE INFORMATION ······················· ····· 15-3 REAR BRAKE ················································15-4 TROUBLESHOO TING ··················· ··············· 15-3 REAR SHO C K ABSORBER ···················· ·······15-7 1 5- 1...
Page 225 REAR WHEEL/BRAKE/SUSPENSION 26 N·m (2.7 kgf·m, 20 lbf.ft) � / 1 1 8 N·m ( 1 2.0 kgf·m, B7 1bf.ft) 1 5-2...
Page 226 Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Use only tires marked "TUBELESS" and tubeless valve stems on rims marked "TUBELESS TIRE APPLICABLE". Use genuine Honda replacement bolts for all suspension pivots and mounting points. SPECIFICATIONS...
Page 227: Rear Brake
REAR WHEEL/BRAKE/SUSPENSION R EAR WHEEL INSPECTION Check the wheel rim runout using dial i ndicators. Actual runout is 1 /2 the total indicator readings. SERVICE liMITS: Radial: 2.0 mm (0.08 in) 2.0 mm (0.08 in) Axial: REMOVAL Place the scooter on its center stand. Remove the muffler (page 3-9).
Page 228 NOTE: REAR WHEEL/BRAKE/SUSPENSION • • DISASSEMBLY Always replace the brake shoes as a set. Mark all parts during disassembly so they can be placed back in the original locations. Loosen the rear brake adjusting nut. Remove the brake shoes and springs by spreading the brake shoes.
Page 229 REAR WHEEL/BRAKE/SUSPENSION ASSEMBLY FELT SEAL BRAKE ARM BOLT BRAKE SHOES JOINT PIN Apply grease to the brake cam sliding su rface. Install the brake cam into the brake panel. Apply oil to the felt seal and install it onto the brake cam.
Page 230: Rear Shock Absorber
REAR WHEEL/BRAKE/SUSPENSION Install the return spring between the belt case and brake arm. Install the joint pin on the brake arm. Connect the brake cable to the joint pin and install the adjusting nut. BRAI<E CABLE JOINT PIN Apply grease to the anchor pin and brake cam slid ing surfaces.
Page 231 REAR WHEEL/BRAKE/SUSPENSION Remove the air cleaner housing bolts. Carefully lift the air cleaner housing up, remove the � SHOCK ABSORBER bolts and rear shock absorber. INSPECTION Check the damper unit for leakage or other damage. SHOCK ABSORBER Replace the shock absorber assembly if necessary. INSTALLATION Install the rear shocl<...
Page 232: Charging System Inspection
1 6. BATTERY/CHARG I N G SYSTEM CHARGING SYSTEM INSPECTION ..... 16-7 SYSTEM DIAGRAM ······················· ·············· 16-2 SERVICE INFORMA TION ·················· ·········· 16-3 ALTERNATOR CHARGING COIL ·················16-8 TROUBLESHO OTING ···················· ·············· 16-5 ENGINE CONTROL MODULE (ECM} ···········16-9 BATTERY ······················································ 16-6 MAIN RELAY ···············································16-11 1 6- 1...
Page 233: System Diagram
BATTERY/CHARGING SYSTEM SYSTEM DIAGRAM MAIN RELAY BATTERY ALTERNATOR/STARTER � MAIN RELAY � IGNITION SWITCH MODUlE (ECM) ENGINE CONTROL BLACK YELLOW •·•·•·• BLUE •·•·•·• GREE N •••·•·• ..WHITE AL TERNATOR / STARTER BROWN ·••··•· 1 6-2...
Page 234 BATTERY/CHARGING SYSTEM SERVICE INFORMATION GENERAL • • WARNING 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 235 BATTERY /CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATION 6 Ah Battery Capacity 0.1 rnA max. Cu rrent leakage Fully charged 13.0 13.2 Voltage I20'C/6B'FI Needs charging Below 1 2.3 V Normal 0.6 A/5 Charging cur- 10 h rent Quick 3A/1 h 190W/5,000 rpm Alternator Capacity 0.05...
Page 236 BATTERY/CHARGING SYSTEM TRO U BLESHOOTING BATTERY IS DAMAGED OR WEAK 1 . BATTERY TEST Remove the battery (page 1 6-6). Check the battery condition using the recommended battery tester. RECOMMENDED BATTERY TESTER: BM-210-AH (U.S.A. only), BM-210 or Battery Mate (MTPOB-0192, U.S.A. only) or equivalent Is the battery in good condition? Faulty battery.
Page 237 BATTERY/CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION Turn the ignition switch to OFF. Remove the inner cover (page 3-5). Remove the fuse box cover by releasing its hook. Disconnect the battery negative (-) cable by remov ing the terminal bolt. Disconnect the fuse box/battery positive (+) cable by removing the terminal bolt.
Page 238 BATTERY/CHARGING SYSTEM BATTERY TESTING Refer to the instructions that are appropriate to the battery testing equipment available to you. TOOL: Battery tester BM-210-AH, BM-210 or BATTERY MATE (MTPOB-0192, U.S.A. only) or equivalent BATTERY CHARGING (U.S.A. only) Refer to the instructions that are appropriate to the battery charging equipment available to you.
Page 239 NOTE: BATTERY /CHARGING SYSTEM • CHARGING VOLTAGE INSPECTION Make sure the battery is in good condition before performing this test. Do not disconnect the battery orany Start the engine and warm it up to the operating cable in the temperature; then stop the engine. NOTE : charging system Connect a tachometer.
Page 240 BATTERY/CHARGING SYSTEM ENGINE CONTROL MODULE ( ECM) SYSTEM INSPECTION Remove the inner cover {page 3-5). Turn the ignition switch to OFF. Disconnect the ECM 26P connector. Check the connector for loose contacts or corroded terminals. Check the following at the harness side connector terminals.
Page 241 BATTERY/CHARGING SYSTEM Check the following at the harness side connector terminals. BATTERY LINE Measure the voltage between the Red wire terminal and ground. When the ignition switch is turned to OFF, there is no voltage and when the ignition switch is turned to ON, there should be voltage.
Page 242 BATTERY/CHARGING SYSTEM REMOVAL/INSTALLATION Remove the inner cover (page 3-5). Turn the ignition switch to OFF. Disconnect the ECM 6P and 26P connectors. Remove the bolts and ECM. Installation is in the reverse order of removal. NOTE: MAIN RELAY • SYSTEM INSPECTION Make sure the battery line and ignition switch cir...
Page 243 BATTERY/CHARGING SYSTEM 2. Main Relay Operation Voltage Inspection Turn the ignition switch to ON. • Measure the voltage between the Red/green wire terminal and ground. • Is there battery voltage? Check for an open or short circuit i n the wire harness. Check the ignition switch (page 1 9- •...
Page 244 1 7 . IG N ITION SYSTEM SYSTEM DIAGRAM ····· ........ 17-2 IGNITION COIL ·············································17-7 IGNITION TIMING ·················· ····················· · 17-7 SERVICE INFORMAT ION ················· ··········· 17-3 TROUBLE SHOOTING ······················· ··········· 17-4 THRO T TLE POSITION SENSOR ··················17-8 IGNITION SYSTEM INSPECTION ···············...
Page 245: Ignition System
IGNITION SYSTEM SYSTEM DIAGRAM THROTILE POSITION SENSOR IGNITION SWITCH ' · MAIN FUSE 20A BATIERY IGNITION COIL SPARK PLUG IGNITION PULSE GENERATOR MAIN FUSE IGNITION SWITCH ENGINE STOP SWITCH ENGINE CONTROL MODULE (ECM) SERVICE CHECK CONNECTOR IGNITION PULSE GENERATOR THROlTLE SENSOR BLACI( •·•·•·•...
Page 246 IGNITION SYSTEM • SERVICE INFORMATION • GENERAL • • Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni� tion switch is turned to ON and current is present. • When servicing the ignition system, always follow the steps in the troubleshooting sequence on (page 17-4). The ignition timing cannot be adjusted since the Engine Control Module (ECM) is factory preset.
Page 247 IGNITION SYSTEM TROUBLESHOOTIN G 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) Temporarily exchange the ignition coil with the other good one and perform the spark test.
Page 248 NOTE: IGNITION SYSTEM • IGNITION SYSTEM I NSPECTION • If there is no spark at the plug, check all connec • tions for loose or poor contact before measuring the peak voltage. Use a commercially available digital multimeter (impedance 1 0 MQ/DCV minimum). The display value differs depending upon the internal impedance of the multimeter.
Page 249 �GNITION SYSTEM Cranl< the engine with the kiclcstarter and measure Avoid touching the the ignition coil primary peak voltage. spark plug and tester probes to PEAK VOLT AGE: 80 V minimum prevent electric shock. If the peak voltage is lower than specified value, fol low the checks described in the troubleshooting chart (page 1 7-4).
Page 250: Ignition Timing
IGNITION SYSTEM Remove the floor step (page 3-7). 6P CONNECTOR Disconnect the alternator/starter 6P connector and connect the peak voltage tester or adaptor probes to the connector terminals of the pulse generator/ starter side. In the same manner as at the ECM connector, mea •...
Page 251 IGNITION SYSTEM Read the ± instructions for Connect the timing light to the spark plug wire. timing fi g ht Start the engine, let it idle and check the ignition operation. timing. IDLE SPEED: 2,000 100 rpm The ignition timing is correct if the "F" mark on the flywheel aligns with the index mark at idle.
Page 252 IGNITION SYSTEM INPUT VOLTAGE INSPECTION Remove the floor step (page 3-7). " n". Disconnect the throttle position sensor 3P connec tor. Turn the ignition switch to ON and engine stop switch to Measure the input voltage between the Yellow/red (+) and Blue/green (-) wire terminals of the wire har ness side connector.
Page 253: Data Reset
NOTE: IGNITION SYSTEM • DATA RESET • You must reset the ECM input data when the throttle position sensor is removed. Do not touch and rotate the throttle grip while resetting the throttle position sensor. Remove the fuse box cover (page 1 6-6). 1.
Page 254: Electric Starter
1 8 . ELECTRIC STARTER SYSTEM DIAGRAM ........18-2 STARTER RELAY ·························· ········· ·······18-6 SERVICE INFORMAT ION ·· ························ ·· 18-3 ENGINE CONTROL MODULE (ECM} ···········18-8 TROUBLESHOOT ING ········ ························· · 18-4 1 8- 1...
Page 255 ELECTRIC STARTER SYSTEM DIAGRAM REAR BRAKE LIGHT SWITCH FRONT BRAKE LIGHT SWITCH IGNITION SWITCH THROTTLE POSITION SENSOR MAIN FUSE 20A BATTERY TOR/STARTER STARTER SWITCH ..BLACK YELLOW "" ..BLUE Y/Bu ..Bu/G GREEN ....WHITE ENGINE STOP SWITCH THROTTLE SENSOR ..
Page 256 ELECTRIC STARTER SERVICE INFORMATION • GENERAL • Some electrical components may be damaged if terminals or connectors are connected or disconnected while the igni- tion switch is turned to ON and current is present. When servicing the electric starter, always follow the steps in the troubleshooting sequence on (page 1 8 : 4). •...
Page 257 E LECTRIC STARTER TROU BLESHOOTIN G Alternator/Starter does not turn (Flywheel does not turn) 1. Fuse Inspection Check for a blown main fuse (20A) and sub fuses ( 1 0A). Is either fuse blown? Replace the fuse. GO TO STEP 2. 2.
Page 258 ELECTRIC STARTER 8. Angle Sensor Circuit Inspection • I nspect the angle sensor circuit at the pulse generator/starter 6P connector side (page 18-8). • Does continuity exist?; Is the voltage normal? • Open circuit i n the Green wire between the pulse generator/starter 6P connector and ground.
Page 259: Starter Relay
ELECTRIC STARTER STARTER RELAY REMOVAL/INSTALLATION Remove the inner cover (page 3-5). Disconnect the battery negative (-) cable and remove the fuse box cover (page 1 6-6). Remove the terminal bolt and disconnect the fuse box/battery positive (+) cable. Remove the starter relay from the fuse box. Install the removed parts in the reverse order of removal.
Page 260 GROUND LINE Turn the ignition switch to OFF. Disconnect the ECM 26P connector and check the connector for loose contacts or corraded terminals. Check for continuity between the Yellow wire termi nals of the ECM 26P connector and starter relay switch connector.
Page 261 ELECTRIC STARTER ENGINE CONTROL MODULE ( ECM ) NOTE: • STARTER SWITCH CIRCUIT INSPECTION Make sure the brake light circuit is normal before performing this i nspection (page 19-22). Remove the front cover (page 3-6). Disconnect the ECM 26P connector and brake light switch connectors.
Page 262 1 9 . LIG HTS/M ETERS/SWITCH E S 1 9-2 SYSTEM LOCATION · F UEL RESERVE INDICATOR/ ........F UEL RESERV E SENSOR ·...
Page 263 LIGHTS/METERS/SWITCHES SYSTEM LOCATION REAR BRAKE LIGHT SWITCH SPEEDOMETER ENGINE STOP FRONT BRAKE LIGHT SWITCH TURN SIGNAL SWITCH HORN SWITCH STARTER SWITCH DRIVE UNIT FUEL RESERVE SENSOR FUEL PUMP 1 9-2...
Page 264 LIGHTS/METERS/SWITCHES SERVICE I NFORMATION GENERAL • A halogen head light bulb becomes very hot while the head light is on, and remains hot for a while after it is turned off. To avoid being burned, be sure to let it cool down before seJVicing. Note the following when replacing the halogen headlight bulb.
Page 265 LIGHTS/METERS/SWITCHES H EADLIGHTS HEADLIGHT BULB REPLACEMENT A CAUTION A halogen headlight bulb becomes very hot while the headlight is on, and remains hot for a while after it is turned off. To avoid being burned, be sure to let it cool down before ser vicing.
Page 266 LIGHTS/METERS/SWITCHES Headlight is not turned on 1. Headlight Circuit { 1 ) Remove the front cover {page 3-6). 9P CONNECTOR Turn the ignition switch to ON. Measure the voltage between the Black/brown wire terminal {+) of the left handlebar switch 9P connector at the harness side and body ground (-'- ).
Page 267 LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the headlight bulb (page 1 9-4). HEADLIGHT Remove the bolts and headlight. Install the removed parts in the reverse order of removal. Adjust the headlight aim (page 4-17). TURN SIGNAL LIGHT BULB REPLACEMENT Remove the screw and turn signal light lens. While pushing the bulb in, turn it cou nterclockwise HOOK SLOT...
Page 268 LIGHTS/METERS/SWITCHES 2. Turn Signal Switch Inspection I nspect the turn signal switch for continuity (page 1 9-22). - • Does continuity exist?· • Faulty turn signal switch. An open circuit in the Black and/or • Gray wire of the turn signal relay. An open circuit in the G reen/black wire between the turn signal light and ECM.
Page 269 LIGHTS/METERS/SWITCHES BRAKE/TAIL LIGHT BULB REPLACEMENT Remove the screws and brake/tail light lens. RUBBER SEAL LENS While pushing the bulb in, turn it counterclockwise to remove it, and replace it with a new one. Make sure that the rubber seal is installed in posi tion and is in good condition.
Page 270 LIGHTS/METERS/SWITCHES 3. Bral<e Light Circuit Inspection Remove the front cover (page 3-6). With the ignition switch turned to ON, check that the battery voltage is present between the Black wire connector of the brake light switch and body ground. • The brake light switch circuit is normal if battery •...
Page 271 LIGHTS/METERS/SWITCHES TURN SIG NAL INDICATOR BULB REPLACEMENT Remove the turn signal indicator lens. Remove the socket from the stay. Remove the bulb and replace it with a new one. Installation is in the reverse order of removal. HIGH BEAM INDICATOR BULB REPLACEMENT Remove the inner cover I page 3-5).
Page 272: Bulb Replacement
LIGHTS/METERS/SWITCHES SPEEDOMETER BULB REPLACEMENT Disconnect the speedometer cable from the speed meter. Remove the nuts and washers. Remove the speedometer from the stay. Remove the socket and replace the bulb with a new one. lnsta llation is in the reverse order of removal. REMOVAL/INSTALLATION Remove the front cover (page 3-6) Disconnect the speedometer light connectors and...
Page 273 LIGHTS/METERS/SWITCHES FUEL RESERVE INDICATOR/FUEL RESERVE SENSOR NOTE: • LED DRIVE UNIT BATTERY/GROUND LINE INSPECTION Make sure the following items are normal, before performing this inspection - Main fuse (20A). sub fuse (1 OA) - Main relay (page 1 6-1 1 ), Load cut relay (page 1 9-23) - Ignition switch (page 1 9-20) - ECM (page 1 6-9)
Page 274 LIGHTS/METERS/SWITCHES 2. Fuel Indicator Line Inspection Ground the Blue/white wire terminal of the 6P Black connector with a jumper wire. Measure the voltage between the Light green (+) and Green/white (-) wire terminals of the fuel reserve indicator 2P connector. Is there approx.
Page 275 LIGHTS/METERS/SWITCHES FUEl RESERVE SENSOR REMOVAl Remove the floor step (page 3-7). Disconnect the fuel reserve sensor 3P connector. Release the wire from the clamp. Remove the retainer by turning it counterclockwise. Remove the fuel reserve senso r, being careful not to deform or damage the sensor.
Page 276 LIGHTS/METERS/SWITCHES NOTE: COOLANT TEMPERATURE INDICATOR/ • ECT S ENSOR When the coolant temperature exceeds 1 20 oc COOLANT TEMPERATURE INDICATOR (248 "F), the coolant temperature i ndicator will blink. The ECM will then control the ignition and • reduce engine speed to 9 mph ( 1 5 km/h). At this time, check the cooling system and engine far leaks or damage.
Page 277 LIGHTS/METERS/SWITCHES 3. ECT Sensor Circuit Inspection Remove the floor step (page 3-7). Warm up the engine to normal operating tem perature. Stop the engine and disconnect the ECT sensor connector White wire. Ground the white wire with a suitable jumper wire.
Page 278 LIGHTS/METERS/SWITCHES ECT SENSOR INSPECTION Remove the floor step (page 3-7). Drain the coolant from the cooling system (page 7- 6) . Disconnect the ECT sensor connector and remove the ECT sensor. Suspend the ECT sensor in a pan of coolant ( 1 :1 Keep all flammable NOTE: mixture) on an electric heating element and mea...
Page 279 NOTE: LIGHTS/METERS/SWITCHES • F U EL PUMP When the ECM detects a problem in the fuel pump circuit while the engine is running, the engine speed will gradually tower via the ignition circuit until finally the ignition and engine will be stopped.
Page 280 LIGHTS/M HERS/SWITCHES 4. Fuel pump Operation Inspection Connect the 12V battery to the fuel pump 2P con nector as shown. Does the fuel pump operate? Faulty fuel pump. - GO TO STEP 5. 5. Discharge Volume Inspection Remove the floor step (page 3-7). Disconnect the fuel hose from the carburetor.
Page 281: Ignition Switch
LIGHTS/METERS/SWITCHES REMOVAL/INSTALLATION Remove the under cover (page 3-8). Pinch the fuel hose with clamp and d isconnect the hoses from the fuel pump. Remove the bolt, nut, stay and fuel pump. Install the stay by aligning its tab with the frame hole and tighten the nut.
Page 282: Handlebar Switches
LIGHTS/METERS/SWITCHES Disconnect the ignition switch 3P connector. Remove the two screws and ignition switch. Use the new screws and install the removed parts in the reverse order of removal. HANDLEBAR SWITCHES Remove the front cover (page 3-6). Disconnect the right handlebar switch 4P connector and left handlebar switch 9P connector.
Page 283 LIGHTS/METERS/SWITCHES LEFT HANDLEBAR SWITCH TURN SIGNAL SWITCH DIMMER SWITCH COLOR DIMMER SWITCH ( N ) HORN SWITCH TURN SIGNAL SWITCH COLOR 81/Br HORN SWITCH BAT2 FREE PUSH COLOR RIGHT HANDLEBAR SWITCH STARTER SWITCH E N G I N E STOP SWITCH FREE START COLOR...
Page 284 LIGHTS/METERS/SWITCHES HORN INSPECTION Disconnect the horn connectors from the horn. Connect a 1 2V battery to the horn terminals. The horn is normal if it sounds when the 1 2V battery is connected across the horn terminals. LOAD CUT RELAY Remove the inner cover (page 3-5).
Page 285: Wiring Diagrams
20. WIRING DIAGRAMS 20.3 • AFTER ' 05 MOO EL:...
Page 286 WIRING DIAGRAMS '03 - '05 MODEL: (REAR) BRAKE lEFr SERVICE CHECK LIGHT SWICTH CONNECTOR STARTER/ HORN ENGINE STOP SWITCH LOAD CUT RELAY RIGHT FRONT TURN I �' f TURN SIGNAL SIGNAL LIGHT IGNITION SWITCH RELAY MAIN RELAY • J�w HEAD LIGHT �...
Page 287 WIRING DIAGRAMS AFTER '05 MODEL: LEFT ]REAR) BRAKE SERVICE CHECK LEVER SWICTH CONNECTOR RIGHT (FRONT) BRAKE STARTER/ HORN ENGINE STOP SWITCH MAIN RELAY ENGINE CONTROL MODULE(ECMI lOAD CUT RELAY RIGHT FRONTTURN TURN SIGNAL SIGNAL LIGHT RELAY IGNITION SWITCH ll�sw HEAD LIGHT $ ' "...
Page 288 2 1 . TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD POOR PERFORMANCE AT LOW AND ..21·2 TO ST A RT IDLE _.21·5 ......·····-···· 21-3 ENGINE LACKS POWER·······-· POOR PERFORMANCE A T HIGH SPEED-·21·6 -···...
Page 289 ENGINE DOES NOT START OR IS HARD TO START 1. C"Mbutetor Inspection Chect U1-e fuel flow to 'lhe-catbu r.cor . ,. fwl t�itdtlnfl tM cetbwd'or1 Clo-gged tueJ "OM or tuol rittor S6t*inu float valve CJoggcd fuel cap bNatbftr • ffulty fvo l pump •...
Page 290 ENGINE LACKS POWER Drive Trfllnlnspection Robe N tront wheel off tM g.-ound 21nd s pin lt by Mnd. .,... tho ___ 1 • 8!8ke dragging • d•m.gad wheel bearing• • Bent;)JC� 00TOSTEP2. Z. T wo P rOK II,.. Inspection Chedl; lha tJrl prtiSSU(I, ptd.JWe the '"...
Page 291 Chcct level "nd -condition. 1$ thr: engine o;t �;ondltlolll i n g o o d • levei too hlg h • o n level too low • Contamina;ed oil YES -GOT OSTEPS. 8. lgnitiofl Timing ln;.poctiiQn C�ck thO ignition timi119. It;...
Page 292 POOR PERFORMANCE AT LOW AND IDLE SPEED '· Spark Plug lnspecllon flernc)w the spert ptuv 1nd� IJ trnt spJ.trlt pJtJg In tood rottdlrion7 lll1VIoecl Plug nat fftQI.Ie.niiY enough • • tncorrsct •»•rt P'i.ll range • plug 91;p lncorn�ct �>t�aft GOTOSTEP2. Y ES (gnition Timing Inspection Ch-�X:k the ignition timing...
Page 293 POOR PERFORMANCE AT HIGH SPEED Chockll• lg -�mlng. • • FiN)(y ECM • put.. oentt1r01 Ftu ' 1 Y ignition • lmproper'WI!VOIImlng VES - GOTOSTEP2. fuel Une Inspection Oisc:oonecl the f u hose ellhe cnr1Jurc l o1, Oon r/1� fuol flow freely? fu�...
Page 294 POOR HANDLING I .J h Steertno • race too Steerlnv OamO'I Q*I CLOP ri ng • bud blartngs ... m-. P'IY Bent tim • E)reesalvotv warn engine mo\lntlng bushing • frllmo Bent tJcM The seooUtr IIIUMitO one R'Oflll a nd 1t.ar wbeel not M:UNd Fili'Jfty �\...
Page 295 22. 1NDEX 4·5 AIR CLEANER flOOR STEP···--··--····-·--·········--···-··----····-·· 3- 7 ....14•111 ALTERNATOR CHARGING l6>8 ..COIL FORK ..- ..-..� ..

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Honda 2003 NPS50 Ruckus Service Manual

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