Table Of Contents - Honda 2003 NPS50 Ruckus Service Manual

Table of Contents

Service Rules2
Model Identification2
Serial Numbers3
General Information4
Labels4
General Specifications5
Lubrication System Specifications6
Fuel System Specifications6
Cooling System Specifications6
Cylinder Head/Valves Specifications7
Kickstarter/Drive Pulley/Driven Pulley/Clutch Specifications7
Final Reduction Specifications7
Crankshaft/Piston/Cylinder Specifications8
Front Wheel/Brake/Suspension/Steering Specifications8
Rear Wheel/Brake/Suspension Specifications8
Battery/Charging System Specifications9
Ignition System Specifications9
Lights/Meters/Switches Specifications9
Standard Torque Values10
Engine & Frame Torque Values10
Lubrication & Seal Points13
Cable & Harness Routing15
Emission Control Systems34
Source Of Emissions34
Crankcase Emission Control System34
Exhaust Emission Control System35
Secondary Air Supply System35
Oxidation Catalytic Converter36
Noise Emission Control System36
Technical Features37
Pcv (Positive Crankcase Ventilation) (After '05 Model)38
Frame/Body Panels/Exhaust System39
Table Of Contents39
Frame/Body Panels/Exhaust System Body Panel Locations40
Frame/Body Panels/Exhaust System Service Information41
Frame/Body Panels/Exhaust System Troubleshooting41
Seat Removal42
Seat Installation42
Seat Rail Removal/Installation43
Inner Cover Removal43
Inner Cover Installation43
Front Cover Removal/Installation44
Floor Step Removal45
Floor Step Installation45
Under Cover Removal/Installation46
Rear Fender Removal/Installation46
Muffler Removal47
Muffler Installation47
Muffler Protector Removal/Installation47
Maintenance48
Maintenance Service Information49
Maintenance Specifications49
Torque Values49
Maintenance Schedule50
Fuel Line51
Throttle Operation51
Air Cleaner52
Engine Breather53
Spark Plug53
Valve Clearance Inspection55
Valve Clearance Adjustment56
Engine Oil Level Check57
Recommended Engine Oil57
Engine Oil Change58
Engine Oil Strainer Screen59
Engine Idle Speed59
Radiator Coolant60
Cooling System60
Brake System63
Brake Lock-Operation63
Headlight Aim64
Front Suspension64
Rear Suspension64
Nuts, Bolts, Fasteners65
Wheels/Tires65
Steering Head Bearings66
Lubrication System67
Lubrication System Diagram68
Lubrication System Service Information69
Lubrication System Troubleshooting69
Lubrication System Torque Values69
Oil Pump Removal70
Oil Pump Disassembly71
Oil Pump Inspection71
Oil Pump Assembly72
Oil Pump Installation73
Fuel System75
Fuel System Component Locations76
Fuel System Service Information77
Fuel System Torque Values77
Fuel System Tools77
Service Inf Ormation77
Fuel System Troubleshooting78
Engine Won't Start78
Engine Stall, Hard To Start, Rough Idling78
Lean Mixture78
Air Cleaner Housing Removal/Installation79
Carburetor Removal81
Carburetor Disassembly82
Vacuum Chamber83
Starting Enrichment (Se) Valve83
Float Chamber84
Carburetor Cleaning85
Carburetor Assembly86
Float Level Inspection87
Carburetor Installation89
Pilot Screw Adjustment92
Idle Drop Procedure92
Tentative Idle Speed92
Final Opening92
P I Lot Screw Adj Ustment (After '05 Model)93
High Altitude Adjustment {After ' 05 Mod94
Input Voltage Inspection95
Resistance Inspection95
Starting Enrichment {Se) Valve95
Operation Inspection96
Pair Control Valve Removal/Installation97
Pair Check Valve Inspection97
Pcv Control Solenoid Valve/Pcv Reed Valve Removal/Installation98
Fuel Tank Removal/Installation102
Pcv Reed Valve102
Cooling System Flow Pattern105
Cooling System Service Information106
Cooling System Torque Values106
Radiator Cover106
Cooling System Troubleshooting107
Coolant System Testing108
Coolant (Hydrometer Test)108
Coolant Specific Gravity Chart108
Radiator Cap/System Pressure Inspection109
Coolant Replacement109
Air Bleeding110
Water Pump/Thermostat Removal111
Thermostat Inspection113
Thermostat Installation113
Radiator Removal115
Radiator Installation116
Radiator Reserve Tank Removal/Installation117
Engine Removal/Installation119
Engine Removal/Installation Component Locations120
Engine Removal/Installation Service Information121
Engine Removal/Installation Specifications121
Engine Removal122
Engine Installation125
Cylinder Head/Valves127
Cylinder Head/Valves Component Locations128
Cylinder Head/Valves Service Information129
Cylinder Head/Valves Torque Values129
Cylinder Head/Valves Tools130
Cylinder Head/Valves Troubleshooting131
Troubleshoo Ting131
Cylinder Compression Test132
Cylinder Head Cover Removal132
Camshaft/Rocker Arms Removal133
Camshaft Inspection135
Rocker Arm//Shaft135
Side Spring135
Cylinder Head Removal136
Cam Chain Tensioner Lifter136
Cylinder Head Disassembly137
Cylinder Head Inspection138
Cylinder Head Valve Spring138
Valve/Valve Guide138
Valve Guide Replacement139
Cam Chain Tensioner/Guide139
Valve Seat Inspection/Refacing Inspection140
Cylinder H Ead Assembly143
Cylinder Head Installation144
Camshaft/Rocker Arm Installation145
Rocker Arm Holder Assembly145
Cylinder Head Cover Installation148
Kickstarter/Drive Pulley/Driven Pulley/Clutch149
Kickstarter/Drive Pulley/Driven Pulley/Clutch Component Locations150
Kickstarter/Drive Pulley/Driven Pulley/Clutch Service Information151
Kickstarter/Drive Pulley/Driven Pulley/Clutch Torque Values151
Kickstarter/Drive Pulley/Driven Pulley/Clutch Tools152
Kickstarter/Drive Pulley/Driven Pulley/Clutch Troubleshooting153
Belt Case Cover Removal154
Belt Case Cover Installation154
Kickstarter Disassembly154
Kickstarter Inspection155
Kickstarter Assembly156
Drive Pulley Removal157
Drive Pulley Inspection158
Drive Belt158
Weight Roller158
Movable Drive Face159
Clutch/Driven Pulley Removal160
Clutch/Driven Pulley Disassembly160
Clutch Disassembly161
Clutch Outer162
Clutch Shoe Lining162
Driven Face Spring162
Driven Face/Movable Driven Face162
Driven Face Bearing Replacement163
Driven Face Bearing Assembly164
Driven Face Bearing Installation166
Final Reduction167
Final Reduction Component Locations168
Final Reduction Service Information169
Final Reduction Torque Values169
Final Reduction Tools169
Final Reduction Troubleshooting170
Final Reduction Oil Level Check171
Final Reduction Disassembly171
Recommended Final Reduction Oil171
Transmission Disassembly171
Drive Shaft Removal172
Drive Shaft Inspection173
Final Reduction Bearing Replacement174
Final Reduction Assembly175
Alternator/Starter179
Alternator/Starter Component Locations180
Alternator/Starter Service Information181
Alternator/Starter Torque Values181
Alternator/Starter Tools181
Alternator/Starter Removal182
Alternator/Starter Installation183
Crankshaft/Piston/Cylinder185
Crankshaft/Piston/Cylinder Component Locations186
Crankshaft/Piston/Cylinder Service Information187
Crankshaft/Piston/Cylinder Torque Values187
Crankshaft/Piston/Cylinder Troubleshooting188
Troubleshooti Ng188
Crankcase Separation189
Crankshaft/Piston189
Crankshaft Removal189
Piston Removal190
Crankshaft Inspection190
Piston/Cylinder Inspection192
Piston Installation194
Crankshaft Installation194
Crankcase Assembly195
Front Wheel/Brake/Suspension/Steering197
Front Wheel/Brake/Suspension/Steering Component Locations198
Front Wheel/Brake/Suspension/Steering Service Information199
Front Wheel/Brake/Suspension/Steering Torque Values199
Front Wheel/Brake/Suspension/Steering Tools200
Front Wheel/Brake/Suspension/Steering Troubleshooting202
Front Wheel Removal203
Front Wheel Inspection203
Front Wheel Disassembly204
Wheel Bearing204
Front Wheel Assembly205
Front Wheel Installation206
Front Brake Removal207
Front Brake Inspection207
Front Brake Disassembly207
Fork Removal211
Fork Disassembly211
Fork Inspection212
Fork Assembly213
Fork Installation214
Handlebar Removal215
Handlebar Installation217
Steering Stem Removal219
Bearing Replacement220
Rear Wheel/Brake/Suspension224
Rear Wheel/Brake/Suspension Component Locations225
Rear Wheel/Brake/Suspension Service Information226
Rear Wheel/Brake/Suspension Troubleshooting226
Rear Wheel/Brake/Suspension Torque Values226
Rear Wheel Inspection227
Rear Wheel Removal227
Rear Brake Inspection227
Rear Wheel Disassembly228
Rear Wheel Assembly229
Rear Shock Absorber Removal230
Rear Shock Absorber Inspection231
Rear Shock Absorber Installation231
Battery/Charging System232
Charging System Inspection232
Battery/Charging System Diagram233
Battery/Charging System Service Information234
Battery Charging234
Battery Testing234
Battery/Charging System Tools235
Battery/Charging System Troubleshooting236
Battery Is Damaged Or Weak236
Battery Removal/Installation237
Voltage Inspection237
Current Leakage Test238
Alternator Charging Coil Inspection239
Charging Voltage Inspection239
Engine Control Module (Ecm) System Inspection240
Regulator/Rectifier Circuit Inspection240
Ignition Switch Circuit Inspection241
Main Relay System Inspection242
Ignition System244
Ignition System Diagram245
Ignition Coil245
Ignition System Service Information246
Ignition System Tools246
Ignition System Troubleshooting247
No Spark At Plug247
Ignition System Inspection248
Ignition Coil Primary Peak Voltage248
Ignition Pulse Generator Peak Voltage249
Ignition Coil Removal/Installation250
Ignition Timing250
Throttle Position Sensor System Inspection251
Data Reset253
Electric Starter254
Electric Starter System Diagram255
Electric Starter Service Information256
Electric Starter Troubleshooting257
Starter Relay Removal/Installation259
Starter Relay Operating Inspection259
Starter Relay Circuit Inspection259
Ground Line260
Starter Circuit Inspection260
Engine Control Module (Ecm)261
Starter Switch Circuit Inspection261
Angle Sensor Circuit Inspection261
Lights/Meters/Switches262
Lights/Meters/Switches System Location263
Lights/Meters/Switches Service Information264
Lights/Meters/Switches Torque Values264
Headlight Bulb Replacement265
Headlight Inspection265
Headlight Is Not Turned On266
Headlight Removal/Installation267
Turn Signal Light Bulb Replacement267
Turn Signal Light Inspection267
Turn Signal Light Removal/Installation268
Brake/Tail Light Bulb Replacement269
Brake/Tail Light Inspection269
Brake/Tail Light Removal/Installation270
Turn Signal Indicator Bulb Replacement271
High Beam Indicator Bulb Replacement271
Speedometer Bulb Replacement272
Speedometer Removal/Installation272
Fuel Reserve Indicator/Fuel Reserve Sensor273
Led Drive Unit Battery/Ground Line Inspection273
Fuel Indicator Line Inspection274
Resistor Line Inspection274
Resistor Inspection274
Fuel Reserve Sensor Removal275
Fuel Reserve Sensor Installation275
Coolant Temperature Indicator/Ect Sensor276
Ect Sensor Circuit Inspection277
Ect Sensor Inspection278
Fuel Pump System Inspection279
Fuel Pump Operation Inspection280
Discharge Volume Inspection280
Fuel Pump Inspection280
Ignition Switch Inspection281
Ignition Switch Removal/Installation281
Handlebar Switches282
Brake Light Switch283
Left Handlebar Switch283
Right Handlebar Switch283
Turn Signal Switch283
Horn Inspection284
Load Cut Relay284
Wiring Diagrams285
Troubleshooting288
Engine Does Not Start Or Is Hard To Start289
Engine Lacks Power290
Poor Performance At Low And Idle Speed292
Poor Performance At High Speed293
Poor Handling294
Index295