I am very pleased to have found the cyclepedia. I needed to rebuild my engine and the online manual I subscribed to is very thorough and provides all the information I needed. The Cyclepedia manual is a good alternative to the Honda Ruckus factory scooter service manual. I liked the immediate access which saved on shipping costs. Love the color pictures. Your online service manual for the Honda Ruckus is a very helpful tool for inspecting and working on my scooter. Just want to say thanks for the Honda Ruckus online service manual.
Great product, really helped. You must be logged in to post a comment. Page Table Of Contents 6. For fuel pump inspection, refer to page 1 Disconnect the engine breather and vacuum piston hoses from the air cleaner housing.
Release the engine breather drain hose from the clamp. Be careful not to Remove the carburetor as an assembly. Disconnect the water hose. Loosen the insulator band screw and remove the insulator from the intake manifold. Remove the spring and jet needle from the vacuum piston. 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. They can Slow jet easily be scored or - Needle jet 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. 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.
Align the tab of the carburetor with the tab of the insulator. 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. Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate a 50 rpm change. Warm up the engine to operating temperature. Ride the scooter for approximately 1 0 minutes. Air should flow into the circuit. If the air is not drawn in, check the air supply hose for clogs.
Check the reed valve for damage or fatigue. Install the PAIR check valve into the valve cover as shown. Remove the 0-ring from the solenoid valve.
Tighten the solenoid valve bolts securely. Always let the engine and radiator cool down before removing the radiator cap.
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 Page Coolant Replacement Mix only distilled, low mineral water with the rec- om mended antifreeze. Remove the four screws and radiator cover.
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. Disconnect the water hoses. Remove the bolts and water pump. Remove the D-ring from the water pump. Heat a pan of water with an electric heating element Keep flammable to operating temperature for 5 minutes.
Install the wire band onto the stay. Connect the water hoses. Install the following: - Ignition coil page - Floor step page Fill and bleed the cooling system page Install the water pipe and align the guide of the crankcase with the water pipe as shown.
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. Remove the radiator reserve tank by releasing its grommet from the frame stay. Page 8. Drain the engine oil page Remove the bolts, clamps and ground wire. Remove the rear brake arm adjusting nut, joint pin and spring.
Disconnect the engine breather hose and ignition coil wire connectors. Place a floor jack or other adjustable support under the frame. Remove the engine mounting nut. Pull out the engine mounting bolt, then remove the engine from the frame. The jack height must be continually adjusted to relieve stress from the mounting fasteners. Tighten the engine mounting nut to the specified torque. Page 9. The cylinder head and valves can be serviced with the engine installed in the frame.
Flat cutter, 22 mm 32" IN Flat cutter, 20 mm 32" 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 hose is smoky, check for a seized piston ring page 1 Stop the engine and remove the spark plug cap and spark plug page 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. 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. 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.
0コメント