Honda Ruckus NPS50 Service Manual, - Honda Spree and Elite 50 Forums - Free repair manual for Honda RUCKUS NPS50 SERVICE MANUAL
Read these labels carefully and don't remove them. If a label comes off or becomes hard to read, Safety and information labels on your scooter provide important safety information and may contact your dealer for a replacement. Page 12 Safety Labels Page Riding Precautions Riding Precautions Riding Precautions Boots or Riding Shoes Sturdy boots with non-slip soles and ankle protection Break-in Period Jacket and Pants During the first 60 miles km of running, Protective, highly visible, long-sleeved jacket follow these guidelines to ensure your scooter's future reliability and performance.
Page 15 Riding Precautions Exercise caution on low traction surfaces. Follow these guidelines to protect the engine, To lower the center stand, stand on the left fuel system and catalytic converter: side of the scooter. Use only unleaded gasoline. Apply throttle gradually. Obey the speed limit. Starting the Engine P. Avoid revving the engine. Starting the Scooter P.
Park on a firm level surface. Use the stand and lock the The brake light will indicate steering. Stopping If pulling off the road, signal early enough to show traffic that you are pulling over, and pull over smoothly.
Page 25 Indicators If one of these indicators does not come on when it should, have your dealer check for problems. Turn signal indicator High coolant temperature indicator If it comes on while riding: P. Turns engine off. LOCK Locks steering. Engine stop switch Should normally remain in the Run position. Page 27 Steering Lock Locking Turn the handlebar all the way to the left. Lock the steering when parking to help Push the key down, and turn the ignition prevent theft.
A U-shaped wheel lock or similar device is Jiggle the handlebar if the lock is difficult also recommended. Page 28 Rear Brake Lock Be sure the rear brake lock is applied while Rear brake starting and warming up the engine.
The rear brake lock will not function if the rear brake is not adjusted properly. Page 29 Starting the Engine Start your engine using the following Place the scooter on its center stand. Lock the rear brake. Release the start button Do not operate the kickstarter while the as soon as the engine starts. Push the scooter forward off the center stand. To decelerate: Close the throttle.
Lock the rear brake lock. Open Keep throttle closed. Close Accelerate Get on the scooter. Decelerate Mount the scooter from the left side, keeping at least one foot on the ground. Page 33 Braking Close the throttle and apply the front and rear brake levers together. Do not apply the brake lock while riding. It may cause the wheel to lock, reducing control of the scooter.
Rear brake lever Front brake lever Tank capacity: 1. You can be burned or Make sure that the arrow marks on the seriously injured when handling fuel.
Page 36 Storage Equipment Helmet Holder Locking The helmet holder is located at the left seat Hang your helmet on the holder pin and rail.
Remove the key. Helmet holder Use the helmet holder only when parked. Document bag Seat hook Screw To open the seat Push the seat hook and lift the seat. To close the seat Lower the seat. An optional larger tool kit may be available. Check with your Honda dealer's parts department. Importance of Maintenance Page Importance Of Maintenance Importance of Maintenance For information about the exhaust emission and Importance of Maintenance noise emission requirements of the U.
Page 40 Importance of Maintenance Follow these guidelines when performing Maintenance Safety maintenance. Always read the maintenance instructions Stop the engine and remove the key. Page Maintenance Schedule Maintenance work should be performed in new owner. Your dealer meets all of these requirements. Keep an accurate record of maintenance to help ensure that your scooter is properly maintained. Page 42 Inspect clean, adjust, lubricate, or replace, if necessary dealer, unless you have the necessary tools and are Replace mechanically skilled.
In the interest of safety, have your scooter serviced by your dealer. A pre- Brake levers operate normally. Page 45 Maintenance Fundamentals Periodic Checks You should also perform other periodic maintenance checks at least once a month regardless of how often you ride, or more often if you ride frequently.
Also, check the odometer reading against the Maintenance Schedule and perform all maintenance that is due. When ordering colored components, specify the model name, color, and code mentioned on the color label. You do not have to check the battery electrolyte level or add distilled water.
Clean the battery terminals if they become dirty or corroded. Page 49 Bump starting is also not 30 days using a charger designed specifically for recommended. Read the information that came with Installing non-Honda electrical accessories can Have your scooter inspected by label to make sure that the oil satisfies all of the your dealer.
For example, the of antifreeze and distilled water. Page 54 Maintenance Fundamentals Use only tubeless tires on this scooter. Page 55 Maintenance Fundamentals Tire Identification Number TIN Air Cleaner The tire identification number TIN is a group This scooter is equipped with a viscous type air of numbers and letters located on the sidewall cleaner element which cannot be cleaned with of the tire. Remove the inner cover. Negative terminal Positive terminal Release the tab, then remove the fuse box cover.
Remove the battery taking care not to drop the terminal nuts. Installation Install the parts in the reverse order of removal. Screws Release the tabs, then remove the inner cover. Inner cover Tabs Remove the maintenance lid. Turn the ignition switch to the OFF Lower position and wait for 2 to 3 minutes.
NOTICE If the engine oil is below or near the lower Overfilling with oil or operating with insufficient level mark, add the recommended engine oil. Do not mix P. Turn the ignition switch to the OFF position and wait for 2 to 3 minutes. Place your scooter on its center stand on a firm, level surface.
Tighten the drain bolt. Speed Open the seat. Air cleaner housing cover Page Coolant Coolant Checking the Coolant If the coolant level is dropping noticeably or the reserve tank is empty, you likely have a serious leak. Have your scooter inspected by Check the coolant level in the reserve tank your dealer.
Place your scooter on its center stand on Adding Coolant a firm, level surface. Ruckus Nps50 Service Manual. Uploaded by Oscar Eduardo Bejarano. Document Information click to expand document information Description: Service manual for honda ruckus. Did you find this document useful? Is this content inappropriate? Report this Document. Description: Service manual for honda ruckus. Flag for inappropriate content. Download now. Jump to Page. Search inside document. Parts that do not meet Honda's design specifications may cause damage to the scooter.
Use the spacial tools designed for this product to avoid damage and incorrect assembly. Use only metric tools when servicing the scooter. Metric bolts, nuts and screws are not interchangeable with English fasteners. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.
When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified.
Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. After reassembly, check all parts for proper installation and operation. Route all electrical wires as shown in the Cable and Harness Routing page N is stamped on the left side of the frame. The engine serial number is stamped on the left side of the belt case.
When ordering color-coded parts, always specify the designated color code. The safety certification label is attached on the left side of the frame. INEX 4. D- — V minimum Ignition pulse generator peak voltage 0. NOTE: 1. Apply oil to the threads and seating surface. Apply sealant to the threads. Apply a locking agent to the threads.
ALOC bolt: replace with a new one. Final shaft seating surface belt case side Countershatt seating surface Molybdenum disulfide grease Apply 0. Apply 0. Fill up 2 cc per each bearing. Fill up 1. Apply 38g per each bearing. Disconnect the air suction hoses from the PCV con- B 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. Check the bushings for wear, deterioration or dam- 5 age.
Remove the pivot caps, bolts and engine hanger link. Check the rubber stopper and bushings for damage, wear or deterioration. Install and tighten the engine hanger link bolts to the specified torque.
Fill and bleed the cooling system page N-m 1. Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection. Camshaft and rocker arm lubricating oil is fed through oil passages in the cylinder head, Clean the oil passages before assembling the cylinder head.
Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. IN ATS — 4. Cam sprocket bolt 8. Cam chain tensioner lifter screw 4. Nem 0. Nem 1. Interior cutter, A, Cutter holder, 4. These problems can be diagnosed by a compression test or by tracing engine noises to the top-end with a sounding rad or stethoscope.
If the hose is smoky, check for a seized piston ring page Stop the engine and remove the spark plug cap and spark plug page Connect compression gauge to the spark plug - hole. To avoid discharging Open the throttle all the way and crank the engine the battery, donot with the kick starter or electric starter until the operate the starter gauge reading stops rising. Disconnect the engine breather and air supply hoses. Remove the bolts and cylinder head cover. Remove the O-rings from the cylinder head cover.
Make sure the cam lobe faces the cylinder side TDC on the compression stroke. Move the rocker arms to the spring side and remove! Mark all shims to ensure correct reassembly in their original locations. The shims can be easily removed with tweezers ora magnet. Remove the screw and O-ring from the cam chain tensioner lifter. Turn the tensioner shaft clockwise with a special tool to hold the tensioner in the fully retracted posi- tion.
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. Loosen the outside cylinder head bolts. Remove the bolts and stopper plate. Remove the camshaft while pressing down on the valve side of the rocker arm. Remove the rocker arm shafts, O-ring, rocker arms and springs. Refer to page for cam chain tensioner and cam chain guide removal.
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.
Check the cam lobe for excessive wear and damage. Measure the height of each cam lobe. Check the oil holes for clogging. Remove the intake manifold joint bolts. Be careful not ta Remove the bolts and cylinder head. Check the cylinder head for warpage with a straight edge and feeler gauge.
Check each valve for bends, burns, scratches or abnormal wear. Measure each valve stem O. Using a torch to heat the cylinder head may cause warpage. Insert the reamer from the combustion chamber side of the head and always rotate the reamer clock- wise. D, from the correspond- ing guide LD. If the stem-to-guide clearance exceeds the service limit with new guide, also replace the valve. Remove the oil pump driven gear page Remove the dowel pin and cam chain tensioner.
Remove the cam chain guide from the cylinder and crankease grooves. Remove the cam chain. Coat the cam chain and timing sprocket with ol.
Installation is in the reverse order of removal. Chill the replacement valve guides in a freezer for 4 about 7 hour. Do not heat the cyl. Use temperature indicator sticks, available from welding supply stores, to be sure the cylinder head is heated to the proper temperature.
Support the cylinder head and drive the valve guides out of the cylinder head from the combus- tion chamber side. TOOL: Valve guide driver, 4. Install the stopper plate onto the cylinder head as shown. Install the bolts and tighten them in a crisscross pat- tern in two or three steps to the specified torque. Make sure the cam lobe faces the cylinder side TDC on the compression stroke , Install the cam sprocket onto the cam chain, align- ing the index fine on the cam sprocket with the index mark on the stopper plate.
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. F Install the cam chain tensioner on the cylinder and tighten the bolts securely.
Remove the special tool ta cancel the lock of the tensioner lifter. Coat a new O-ring with oil. Install and tighten the lifter screw to the specified torque.
Install new O-rings to the PCV joint and cam chain tensioner lifter groove. Install the PCV joint to the cam chain tensioner. Tighten the bolt to the specified torque. Coat the new O-rings with oil and install them into the grooves of the cylinder head cover. Install the cylinder head cover to the cylinder head. Install the bolts and tighten them in a crisscross pat- tern in two or three steps. Connect the engine breather and air supply hoses.
Install the fuel tank page Remove the bolts, clamp and belt case cover. Remove the rubber seal and dowel pins from the belt case cover. Clean the rubber seal groove of the belt case cover. Install the dowel pins and the rubber seal to the belt case cover.
Install the belt case cover to the belt case by align- ing the dowel pins with the holes. Install and tighten the belt case cover bolts and clamp in a crisscross pattern in two or three steps. Remove the kickstarter driven gear by turning the kickstarter pedal clockwise.
Release the hook end of the return spring from the belt case cover stopper. Remove the snap ring and washer. Check the return spring for fatigue or damage. Check the collar and bushing for wear or damage.
Install the return spring as shown. Apply molybdenum paste 0. Install the kickstarter spindle to the belt case cover and hook the return spring end to the groove of the [ kickstarter 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.
Install and tighten the bolt securely. Apply molybdenum paste to the kickstarter driven gear journal and spring surface. Turn and hold the kickstarter pedal. Install the kickstarter driven gear, aligning the spring end with the groove of the belt case cover and the kickstarter gear with the driven gear.
Install the belt case cover page Remove the drive belt from the crankshaft. Remove the drive face boss from the movable drive face assembly. Remove the ramp plate and weight rollers. Measure the boss O. Install the ramp plate. Install the drive face boss into the movable drive face assembly.
Install the movable drive face assembly onto the crankshaft while holding the ramp plate. Install the drive belt onto the drive face boss. Install the drive pulley face, ratchet plate and washer. Apply oil to the drive pulley face nut threads and seating surface, then install the nut.
Hold the drive pulley face with the special tool and tighten the nut to the specified torque. Hold the clutch outer with the special tool and loosen the clutch outer nut. Remove the drive bolt from the driven pulley. If so, some parts may pop out causing an injury. Repeat this procedure and remove the clutch assembly from the driven face. Remove the clutch shoes and shoe springs. Measure the clutch outer ILD. Measure the thickness of each shoe.
Measure the driven face boss 0. Check the guide grooves for stepped wear or dam- age. Measure the movable driven face I. TOOL: Snap ring pliers. Press the ball bearing into the driven face with the marked side facing up. Press the needle bearing into the driven face with the marked side facing up. Install the washers and E-clips. Be careful not to damage the spline. Install the stopper ring securely.
Do not get any oil and grease on the driven face inside. Clean any oil and grease from the inside of the clutch outer. Bearing remover set, 12 mm not available in U.
Bearing remover shaft not available in U. 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.
If the level is low cil does not flow out , add the rec- ommended oil. Release the engine breather drain hose from the clamp. Remove the brake cable from the cable holder. 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 surface.
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