Honda NSS250/A, NSS250S/AS Reflex Service Manual, 2001–2007 (P/N 61KPB06)

This Honda service and repair manual covers the 2001–2007 NSS250, NSS250A, NSS250S, and NSS250AS Reflex in 25 numbered sections, under P/N 61KPB06.

PDF Access, Diagram Detail, and Page Count

Search, bookmarks, and wiring detail: PDF text search and embedded bookmarks are not available. Small wire-color codes and connector labels on the wiring diagrams require zooming; the checked dense areas remain readable when enlarged.

The ZIP download contains one printable English PDF. Its 401-page total includes both covers, three preliminary pages, and ten memo pages.

Engine, CVT, Chassis, and ABS Service

These selected service topics show part of the manual’s coverage rather than a complete contents list. Other examples include PAIR-system inspection and EVAP purge-control valve testing.

• Engine repair: Engine removal and installation, cylinder-head and valve repair, cylinder/piston inspection, cam timing, crankcase separation, and crankshaft checks.

• CVT and final drive: Drive-pulley, driven-pulley, V-belt, centrifugal-clutch, final-reduction gear and bearing service, plus alternator, flywheel, and starter-clutch work.

• Fuel, lubrication, and cooling: VE3BL carburetor overhaul, starting-enrichment diagnosis, pilot-screw and high-altitude adjustment, oil-pump inspection, cooling-system pressure tests, and water-pump service.

• Brakes and ABS: Circuit-specific bleeding, master-cylinder and caliper overhaul, delay-valve and parking-brake service, ABS blink-code diagnosis, wheel-speed sensor checks, and modulator replacement.

• Suspension and steering: Fork disassembly and rebuilding, steering-stem bearing replacement, wheel inspection, rear-wheel/swingarm service, and rear-shock inspection and replacement.

• Electrical diagnosis: Charging, ignition, and starter tests, switch continuity charts, four wiring-diagram sheets, and model-specific cable and harness routing.

Honda wrote this manual for qualified professional technicians with basic Honda motorcycle, motor scooter, or ATV maintenance knowledge and the proper tools and shop equipment.

Variant and Revision Coverage

The issue page is dated February 2004; revised pages dated December 2006 extend coverage through the 2007 model year and carry the marking MSV 11760 (0612).

Model-specific routing drawings distinguish NSS250, NSS250A, and NSS250S/AS layouts. Body and chassis procedures separate NSS250/A rear-spoiler and body-panel work from NSS250S/AS backrest, grab-rail, and handle-cover hardware.

Post-2003 differences include alternator output, current-leak inspection limits, regulator/rectifier connectors, ignition-switch wiring, harness clamps, and later wiring diagrams.

Powertrain Repair and Service Access

The powertrain sections distinguish in-frame work from engine-out repair. The oil pump, carburetor, water pump, camshaft and rocker arms, CVT, final reduction, and alternator/starter clutch can be serviced with the engine installed. Cylinder-head removal, cylinder/piston service, and crankshaft/crankcase work require engine removal. This distinction helps plan access and engine support before teardown.

Step-by-step procedures cover compression testing, valve-guide replacement, valve-seat inspection and refacing, piston and cylinder measurement, bearing replacement, and reassembly checks. Scheduled maintenance includes valve-clearance adjustment, engine-oil and strainer service, and final-drive oil changes.

The CVT section warns that oil or grease on the V-belt and pulley faces can cause belt slippage; the movable drive face and weight rollers must remain ungreased.

Starting Enrichment and Cooling-System Repair

Starting-enrichment diagnosis covers the battery-powered SE valve controlled by the ignition control module, rather than a conventional alternator-powered thermal valve.

Cooling-system procedures include radiator-cap and system pressure testing, thermostat inspection, coolant replacement and air bleeding, radiator service, and water-pump mechanical-seal replacement. Honda warns that silicate-inhibited coolant can prematurely wear water-pump seals or obstruct radiator passages.

Suspension, Linked Brakes, and Parking Brake

Fork procedures extend through seal replacement, internal inspection, fluid-level measurement, and reassembly. Steering-stem work includes bearing and race replacement.

The hydraulic-brake chapter separates the front circuit from the linked rear circuit. It maps the linked-system bleed branches through the lower front-caliper and rear-caliper bleed points and explains the delay-valve resistance felt at the lever.

Technical-feature pages explain the rear caliper’s automatic adjustment and cable-operated parking-brake mechanisms.

ABS Fault Isolation and Modulator Service

On ABS-equipped NSS250A/AS models, diagnosis runs from self-test and memory clearing through code-directed flowcharts. These address indicator faults, sensor circuits, pulser rings, solenoid valves, wheel-lock conditions, pump/motor and fail-safe relay faults, incorrect tire size, and ECU/modulator failure.

The manual also covers sensor and pulser-ring inspection, modulator removal and installation, and subsequent brake-system filling and bleeding. The modulator is a sealed, maintenance-free assembly; the service coverage concerns diagnosis and replacement.

Electrical Tests, Wiring References, and Tools

Electrical fault-finding includes battery load and current-leak tests, alternator-coil checks, ICM and ignition-pulse peak-voltage tests, TP and ECT sensor measurements, starter-motor and relay inspection, fuel-pump output testing, and meter/sensor checks.

The wiring section contains 2001–2003 and post-2003 sheets for standard and ABS configurations. The post-2003 Standard/ABS headings conflict with the circuits shown: the sheet labeled Standard contains the ABS modulator and wheel-speed sensors, while the sheet labeled ABS omits them. Match the depicted equipment to the scooter’s configuration.

Supporting references include the body-panel removal chart, lubrication-system diagram, cooling-system flow pattern, ABS system diagram, and cable/harness routing views. Torque tables, fluid data, wear limits, and electrical test specifications accompany the relevant procedures.

Factory tool references identify valve spring compressor 07757-0010000, clutch spring compressor 07LME-GZ40200, case puller 07SMC-0010001, and peak-voltage adapter 07HGJ-0020100. The tool list marks the case puller as unavailable in the U.S. and also identifies bearing, seal, steering, and carburetor tools.

Work on brake and fuel systems, hot or pressurized cooling components, batteries, electrical circuits, and a supported scooter must follow Honda’s stated precautions and use the specified equipment and qualified shop judgment.

Selected Float-Level and Thermostat Inspection Data

For the VE3BL carburetor, float-level inspection specifies 18.5 mm (0.73 in). The float is nonadjustable; the manual specifies float-assembly replacement if the level is outside specification.

Thermostat testing specifies an initial opening range of 69–72.5°C (156–163°F), with a minimum valve lift of 3.5 mm (0.14 in) at 80°C (176°F).