The Cyclepedia Honda NPS50 Ruckus 50 scooter online service manual features detailed full-color photographs and color wiring diagrams, complete specifications with step-by-step procedures performed and written by a veteran Honda dealer trained motorcycle technician.
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Attach a piece of wire to the cam chain to prevent it from falling into the crankcase. 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.
Check the cylinder head for warpage with a straight edge and feeler gauge. Insert the reamer from the combustion chamber side of the head and always rotate the reamer clock- wise. TOOL: Valve guide reamer, 4. TOOL: Valve guide driver, 4.
Install the spring retainers. 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. 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. 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 Troubleshoo Ting 1 0.
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. Remove the bolts, clamp and belt case cover. Clean the rubber seal groove of the belt case cover. Release the hook end of the return spring from the belt case cover stopper.
Remove the snap ring and washer. 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. Remove the drive face boss from the movable drive face assembly. Remove the ramp plate and weight rollers. Measure the boss O. Hold the clutch outer with the special tool a n d loosen the clutch outer nut. Repeat this procedure and remove the clutch assembly from the driven face.
Measure the thickness of each shoe. Press the needle bearing into the driven face with the marked side facing up. Install the washers and E-clips. Page Table Of Contents 1 1. 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. Support the scooter with its center stand on a level surface. Remove the final reduction oil check bolt and check whether the oil flows out from the check bolt hole.
Remove the transmission case and drain all oil to the suitable container from the transmission case. Remove the dowel pins. Remove the thrust washers and countershaft. The bearings should turn smoothly a n d quietly. 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. Install the dowel pins. Apply molybdenum grease 0. 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. These services can be done with the engine installed i n the frame. Hold the flywheel with the special tool and loosen the flywheel nut. Remove the flywheel using the special tool. 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. Install the flywheel onto the crankshaft, aligning the key way with the woodruff key. Install the washer and flywheel nut. Page 1 3. The following parts must be removed before separating the crankcase. Remove the rubber seal. Remove the four bolts and center stand from the crankcase. Remove the piston pin out of the piston.
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.
Install the piston with the " I N " mark facing the intake side while compressing the piston rings with your fingers. Tighten the drain bolt to the specified torque. Page 1 4. Page When servicing the front wheel, fork or steering stem, support the motorcycle using a safety stand or hoist.
Use genuine Honda replacement bolts and nuts for all suspension pivots and mounting points. A Bearing remover head, 10 mm Driver Socket wrench, 32 mm KM 1 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. Spin the wheel slowly and read the runout using a dial i ndicator. Drive a new left bearing brake drum side squarely with the sealed side facing up until it is fully seated.
Install the distance collar. 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. Remove the brake panel from the front wheel page 1 Remove the brake cam from the brake panel. Install the brake cam into the brake panel.
Apply oil to the felt seal and install it to the brake cam. Install the brake arm pinch bolt and nut as shown and tighten the nut to the specified torque. Remove the upper fork pinch bolt. Loosen the lower fork pinch bolt and remove the fork tube from the steering stem. Clean the grease within the bottom case. Install the fork tube into the bottom case. Disconnect the right and left handlebar switch 9P and 2P connectors. 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 Install the nut cap. Apply grease to the brake lever pivot screw sliding surface. Install the throttle cable to the lower housing.
Lightly tighten the th rottle cable lock nut. 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. Loosen the top cone race using the special tool. Install the lower bearing onto the stem. Insert the steering stem into the steering head pipe. Temporarily loosen the steering stem top cone race.
Install the lock washer and lock nut. Page Table Of Contents 1 5. Page Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
Use genuine Honda replacement bolts for all suspension pivots and mounting points. Remove the muffler page Mark all parts during disassembly so they can be placed back in the original locations.
Remove the brake shoes and springs by spreading the brake shoes. Apply oil to the felt seal and install it onto the brake cam. Install the joint pin on the brake arm.
Connect the brake cable to the joint pin and install the adjusting nut. Page Charging System Inspection 1 6. Provide adequate ventilation when charging. Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. Cu rrent leakage Fully charged Check the battery condition using the recommended battery tester.
Faulty battery. Remove the inner cover page Remove the fuse box cover by releasing its hook. 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. 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. 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. Remove the bolts and ECM. Check for an open or short circuit i n the wire harness. Page 1 7. The display value differs depending upon the internal impedance of the multimeter.
Do not touch and rotate the throttle grip while resetting the throttle position sensor. Remove the fuse box cover page 1 Page Electric Starter 1 8. When servicing the electric starter, always follow the steps in the troubleshooting sequence on page 1 8 : 4. Fuse Inspection Check for a blown main fuse 20A and sub fuses 1 0A. Is either fuse blown? Replace the fuse. Disconnect the battery negative - cable and remove the fuse box cover page 1 Remove the starter relay from the fuse box. Install the removed parts in the reverse order of removal.
Disconnect the ECM 26P connector and check the connector for loose contacts or corraded terminals. Remove the front cover page Disconnect the ECM 26P connector and brake light switch connectors. Page 1 9. To avoid being burned, be sure to let it cool down before seJVicing. Note the following when replacing the halogen headlight bulb. Adjust the headlight aim page Turn Signal Switch Inspection I nspect the turn signal switch for continuity page 1 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.
Remove the socket from the stay. Remove the bulb and replace it with a new one. Remove the nuts and washers. Remove the speedometer from the stay.
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