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KYMCO ZX Service Manual

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This Service Manual describes the technical feature.s and servicing
procedures for the KYMCO ZX / SCOUT 50.
In this manual, many illustrations and drawings are used to help
servicemen have better understanding.
Section 2 contains the service precautions for all operations and
troubleshooting stated in this manual. Read them carefully before starting
any operation.
Section 3 describes the inspection/adjustment procedures, safety rules and
service information for each part, starting from periodic maintenance.
Sections 4 through 16 give instructions for disassembly, assembly and
inspection of lubrication system, engine, fuel system and electrical
equipment.
Section 17 is the maintenance and inspection directions for the evaporative/
exhaust emission control system. Most sections start with an assembly or
system illustration and troubleshooting for the section. The subsequent
pages give detailed procedures for the section.
PREFACE
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
ZX / SCOUT
50
MARCH 2000

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  • Page 1 ZX / SCOUT PREFACE This Service Manual describes the technical feature.s and servicing procedures for the KYMCO ZX / SCOUT 50. In this manual, many illustrations and drawings are used to help servicemen have better understanding. Section 2 contains the service precautions for all operations and troubleshooting stated in this manual.

  • Page 2: Table Of Contents

    ZX / SCOUT . SPECIFICATIONS TABLE OF CONTENTS SPECIFICATIONS .................. 1 GENERAL INFORMATION ..............2 INSPECTION/ADJUSTMENT ............... 3 LUBRICATION SYSTEM............... 4 ENGINE REMOVAL/INSTALLATION ..........5 CYLINDER HEAD/CYLINDER/PISTON ..........6 A.C. GENERATOR ................. 7 KICK STARTER/DRIVE PULLEY/CLUTCH/DRIVEN PULLEY ..8 FINAL REDUCTION................9 CRANKCASE/CRANKSHAFT ...............10...

  • Page 3: Specifications

    ZX 50 SPECIFICATIONS Oil filter type Full-flow filtration SPECIFICATIONS Name & Model SC10AS Lubrication oil capacity (liter) 0.80 Overall length (mm) 1792 Air cleaner type & No. Wet, single Overall width (mm) Fuel capacity (liter) Overall height (mm) 1053 Type Plunger type ...

  • Page 4: General Information

    ZX / SCOUT . GENERAL INFORMATION __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ ENGINE SERIAL NUMBER/IDENTIFICATION......2- 1 SERVICE PRECAUTIONS ............2- 2 SERVICE INFORMATION............2- 6 TORQUE VALUES ................ 2- 8 SPECIAL TOOLS ................2- 9 LUBRICATION POINTS ............... 2-11 WIRING DIAGRAM ..............

  • Page 5: Engine Serial Number/Identification

    . GENERAL INFORMATION ZX / SCOUT ENGINE SERIAL NUMBER/IDENTIFICATION Location of Engine Serial Number...

  • Page 6: Service Precautions

    ZX / SCOUT . GENERAL INFORMATION lubricants to the specified lubrication points. SERVICE PRECAUTIONS n Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. n After reassembly, check all parts for proper n When tightening bolts or nuts, begin with tightening and operation.
  • Page 7 . GENERAL INFORMATION ZX / SCOUT n If the double connector has a lock, lock it to the specified capacity. at the correct position. n Check if there is any loose wire. Easy confirm n Before connecting a terminal, check for...
  • Page 8 ZX / SCOUT . GENERAL INFORMATION n Do not squeeze wires against the weld or its n Protect wires and harnesses with electrical clamp. tape or tube if they contact a sharp edge or corner. n After clamping, check each harness to make...
  • Page 9 . GENERAL INFORMATION ZX / SCOUT The following symbols represent the servicing methods and cautions included in this service manual. n Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.

  • Page 10: Service Information

    ZX / SCOUT . GENERAL INFORMATION SERVICE INFORMATION ENGINE Standard (mm) Service Limit (mm) Item SC10AS SC10AS  Cylinder head warpage 0.10 Piston O.D.(5mm from bottom of piston skirt) 38.955 38.970 38.90 Cylinder-to- piston clearance 0.10 Piston pin hole I.D.
  • Page 11 ZX / SCOUT . GENERAL INFORMATION FRAME Standard (mm) Service Limit (mm) Item SC10AS SC10AS  Axle shaft runout Radial Front wheel rim runout Axial Front shock absorber spring free length 200.0 182.8 Rear wheel rim runout Brake drum I.D.

  • Page 12: Torque Values

    ZX / SCOUT . GENERAL INFORMATION TORQUE VALUES ENGINE Item Thread dia. (mm) Torque (kg-m) Remarks Cylinder head bolt BF7x115 1.5 1.7 (cold) Clutch drive plate nut 3.5 4.0 Clutch outer nut NH10 3.5 4.5 Drive face nut NH12 5.0 6.0 Oil check bolt 1.0 1.5...

  • Page 13: Special Tools

    ZX / SCOUT . GENERAL INFORMATION SPECIAL TOOLS Tool Name Tool No. Remarks Universal bearing puller E030 Crankshaft bearing removal Lock nut socket wrench F001 Top cone race holding Lock nut wrench, F002 Stem lock nut tightening Crankcase puller E026...

  • Page 14: Wiring Diagram

    ZX / SCOUT . GENERAL INFORMATION ENGINE Lubrication Points Lubricant Remarks Crankcase sliding & movable parts JASO-FC or API-TC Cylinder movable parts JASO-FC or API-TC Transmission gear (final gear) SAE-90# Kick starter spindle bushing Grease Drive pulley movable parts Grease...

  • Page 15: Cable & Harness Routing

    ZX / SCOUT . GENERAL INFORMATION CABLE & HARNESS ROUTING 2-11...
  • Page 16 ZX / SCOUT . GENERAL INFORMATION Rear Stop Switch Wire Front Stop Switch Wire Front Brake Reservoir Rear Brake Cable Throttle Cable Front Brake Fluid Tube Speedometer Cable Ignition Switch Horn Regulator/Rectifier Resistor Front Brake Fluid Tube Speedometer Cable 2-12...
  • Page 17 ZX / SCOUT . GENERAL INFORMATION Throttle Cable Speedometer Cable Rear Brake Cable Front Brake Fluid Tube Wire Harness Speedometer Cable Front Brake Fluid Tube Fuel Unit Ignition Coil 2-13...
  • Page 18 ZX / SCOUT . GENERAL INFORMATION Oil Tube CDI Unit Oil Tank Cap Wire Harness Battery Ignition Coil Fuel Filter Starter Relay 2-14...

  • Page 19: Troubleshooting

    ZX / SCOUT . GENERAL INFORMATION Fuel Unit Fuel Tank Cap Vacuum Tee Oil Tube Oil Pump Ignition Coil TROUBLESHOOTING 2-15...
  • Page 20 ZX / SCOUT . GENERAL INFORMATION ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Symptom Probable Cause Check if fuel reaches carburetor by loosening drain screw. • Empty fuel tank ‚ Clogged float valve Fuel reaches Fuel does not ƒ...
  • Page 21 ZX / SCOUT . GENERAL INFORMATION Check if fuel reaches carburetor by loosening drain screw. • Empty fuel tank ‚ Clogged float valve Fuel reaches Fuel does not ƒ Clogged fuel filter carburetor reach carburetor „ Faulty auto fuel valve...
  • Page 22 ZX / SCOUT . GENERAL INFORMATION • Carburetor not securely tightened ‚ Faulty intake manifold gasket No air leak Air leaks ƒ Deformed or broken carburetor O-ring Remove auto bystarter connecting wire and check if bypass fuel line is clogged.
  • Page 23 ZX / SCOUT . GENERAL INFORMATION • Clogged air cleaner Engine speed does ‚ Clogged fuel filter Engine speed not increase ƒ Clogged exhaust muffler increases sufficiently „ Faulty auto bystarter Check ignition timing (using a timing light). • Faulty CDI unit...
  • Page 24 ZX / SCOUT . GENERAL INFORMATION Check ignition timing. • Faulty CDI unit Incorrect timing Correct timing ‚ Faulty A.C. generator Check carburetor air screw adjustment. • Mixture too rich (turn screw Correctly adjusted Incorrectly adjusted out) ‚ Mixture too lean (turn screw Check carburetor gasket for air leaks.
  • Page 25 ZX / SCOUT . GENERAL INFORMATION • Faulty CDI unit ‚ Loose A.C.G. stator Correct timing Incorrect timing ƒ Faulty A.C. generator Check auto fuel valve for fuel supply. • Empty fuel tank ‚ Clogged fuel tube or filter Fuel flows freely Fuel flow restricted ƒ...
  • Page 26 ZX / SCOUT . GENERAL INFORMATION … Damaged driven pulley shaft splines † Damaged final gear ‡ Seized final gear Motorcycle creeps or • Broken shoe spring engine starts but soon ‚ Clutch outer and clutch weight stuck stops or seems to rush ƒSeized pivot...
  • Page 27 ZX / SCOUT . GENERAL INFORMATION ƒ Shock damper oil leaking • Bent fork tube or shock rod Suspension is too hard ‚ Fork slider and tube binding • Fork tube and spring binding Suspension is noisy ‚ Fork slider and tube binding...
  • Page 28 ZX / SCOUT . GENERAL INFORMATION Check battery circuit by operating turn signals. • Burned out fuse ‚ Weak or dead battery Signals dim, remain Signals operate ƒ Faulty ignition switch properly on or don‘t operate „ Loose or disconnected...
  • Page 29 ZX / SCOUT . GENERAL INFORMATION „ Loose or disconnected Remove fuel unit and connector check operation of … Broken wire harness pointer by moving float up and down. Pointer does not • Faulty float Pointer moves move Check operation of...
  • Page 30 ZX / SCOUT . GENERAL INFORMATION switch wire Signals operate • Faulty or weak battery Signals dim, remain properly on or don‘t operate • Poor starter button connection Relay does not Relay operates ‚ Faulty starter relay operate properly ƒ Loose or disconnected...

  • Page 31: Inspection/Adjustment

    ZX /SCOUT 50 . INSPECTION/ADJUSTMENT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ INSPECTION AND MAINTENANCE SCHEDULE......3- 1 BRAKE SYSTEM................3- 4 MOVING DEVICE................. 3- 5 DAMPING DEVICE............... 3- 6 POWER DRIVE SYSTEM ............. 3- 6 ELECTRICAL EQUIPMENT............3- 7 ENGINE ..................

  • Page 32: Inspection And Maintenance Schedule

    ZX /SCOUT 50 . INSPECTION/ADJUSTMENT INSPECTION AND MAINTENANCE SCHEDULE (Note) 1. means time for inspection. 2. means regular replacement for the specified parts. This inspection and maintenance schedule is based upon average riding conditions. Machines subjected to serve use, or ridden in unusually dusty areas, require more frequent servicing.
  • Page 33 ZX /SCOUT 50 . INSPECTION/ADJUSTMENT Frequency Every Every Inspection & Maintenance Item Judgment Standards Remarks month Preride month months Tire crack and damage Groove Depth: Tire groove and Front: 0.8mm abnormal wear Rear : 0.8mm Imbedded objects, gravel, etc. Torque Values:...
  • Page 34 ZX /SCOUT 50 . INSPECTION/ADJUSTMENT Electrical Battery Terminal connection Equipment Loose connection and Wires damage Frequency Every Every Inspection & Maintenance Item Judgment Standards Remarks month Preride month months Performance and abnormal noise Conditions at low and high Body speeds...
  • Page 35 ZX /SCOUT 50 . INSPECTION/ADJUSTMENT Abnormal Conditions Check if the abnormal Happened Last conditions occur again Time Lubrication points Remove carbon deposits on Others combustion chamber, breather hole and exhaust muffler specified limits through the front brake master BRAKE DRUM/SHOE cylinder check hole.

  • Page 36: Lubrication System

    . LUBRICATION SYSTEM «Wheel Rim/Spoke Plate Damage» Check the wheel rim and spoke plate for wear or Brake Lining Service damage and measure the rim runout. Brake Disk Limit Mark Brake Master Cylinder MOVING DEVICE TIRES «Tire Pressure » Check the tire pressure. Tire pressure should be checked when tires are cold.

  • Page 37: Damping Device

    . INSPECTION/ADJUSTMENT Specified Gear Oil: SAE10W90# Axle Nut Install and tighten the oil check bolt. Torque: 1.0 1.5kg-m Start the engine and check for oil leaks. Rear Wheel Axle Nut DAMPING DEVICE SHOCK ABSORBERS «Oil Leak/Damage» Fully apply the front brake and check the action of the front shock absorber by compressing it several times.

  • Page 38: Electrical Equipment

    . LUBRICATION SYSTEM timing with a timing light. When the engine is running at the specified rpm, the ignition timing is correct if the “F” mark on the flywheel aligns with the index mark on the crankcase within ±2°. Ignition Timing: 15.5°±2°BTDC/2000rpm ELECTRICAL EQUIPMENT IGNITION APPARATUS...

  • Page 39: Engine

    . INSPECTION/ADJUSTMENT Index Mark F Mark Throttle Stop Screw ENGINE BODY «At High and Low Speeds» The engine must be warm for accurate idle speed adjustment. Adjust the idle speed to the specified range by turning the throttle stop screw and air screw. Idle Speed: 2100±100rpm Air Screw...
  • Page 40 . LUBRICATION SYSTEM Air Cleaner combustion chamber and the piston head. LUBRICATION SYSTEM «Oil Filter Cleaning» Disconnect the oil tube at the oil pump side and allow oil to drain into a clean container. Remove the tube clip at the oil tank side and disconnect the oil tube.
  • Page 41 . INSPECTION/ADJUSTMENT Clip If the oil pump is not synchronized properly, the following will occur: • Excessive white smoke or hard starting due to pump control lever excessively open • Seized piston due to pump control lever insufficiently open Oil Filter Clean the oil filter screen with compressed air.

  • Page 42: Others

    . LUBRICATION SYSTEM «Headlight» Adjust the headlight beam by loosening the headlight adjusting bolt and moving the adjusting bolt forward and backward to a proper position. Tighten the adjusting bolt. FUEL SYSTEM «Throttle Grip Free Play» Measure the throttle grip free play. Free Play: 2 6mm Lock Nut If the throttle grip free play does not fall within...
  • Page 43 . INSPECTION/ADJUSTMENT Headlight Adjusting Bolt 3-12...
  • Page 44 ZX /SCOUT 50 . LUBRICATION SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION............4-2 TROUBLESHOOTING ..............4-2 OIL PUMP REMOVAL ..............4-3 OIL PUMP INSPECTION .............. 4-3 OIL PUMP INSTALLATION ............4-4 OIL PUMP BLEEDING ..............4-5...

  • Page 45: Lubrication System

    ZX /SCOUT 50 . LUBRICATION SYSTEM LUBRICATION SYSTEM...

  • Page 46: Service Information

    ZX /SCOUT 50 . LUBRICATION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • Use care when removing and installing the oil pump not to allow dust and dirt to enter the engine and oil line. • Do not attempt to disassemble the oil pump.

  • Page 47: Oil Pump Removal

    ZX /SCOUT 50 . LUBRICATION SYSTEM OIL PUMP REMOVAL Do not allow foreign matters to enter the crankcase. Before removing the oil pump, clean the oil pump and crankcase surfaces. Remove the met-in box. ( ð 12-4) Control Cable Oil Inlet Line...

  • Page 48: Oil Pump Bleeding

    ZX /SCOUT 50 . LUBRICATION SYSTEM • Lubricate the O-ring with grease or engine oil before installation. • Make sure that the oil pump is inserted into the crankcase. • Apply molybdenum disulfide or grease to the pump pinion. Grease or Engine Oil Install the oil pump onto the crankcase.

  • Page 49: Oil Tank

    ZX /SCOUT 50 . LUBRICATION SYSTEM • Air in the oil lines will block oil flow and result in severe engine damage. • Bleed air from the oil lines and oil pump whenever the oil lines or pump have been removed or there is air in the oil lines.
  • Page 50 ZX /SCOUT 50 . LUBRICATION SYSTEM Remove the rear carrier. ( ð 12-5) Remove the frame body cover. ( ð 12-5) Remove the oil meter connector. Remove the two bolts attaching the oil tank. Disconnect the oil inlet line. Drain the oil inside the oil tank into a clean container.

  • Page 51: Engine Removal/Installation

    ZX / SCOUT . ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION............5-1 ENGINE REMOVAL..............5-2 ENGINE INSTALLATION............. 5-4...
  • Page 52 . ENGINE REMOVAL/INSTALLATION ZX / SCOUT SERVICE INFORMATION GENERAL INSTRUCTIONS • Parts requiring engine removal for servicing: Crankcase Crankshaft TORQUE VALUES Engine mounting bolt 4.5 5.5kg-m Rear shock absorber lower mount bolt 2.4 3.0kg-m Engine hanger bracket bolt 3.5 4.5kg-m 4.5 5.5kg-m...

  • Page 53: Engine Removal

    ZX / SCOUT . ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Remove the frame body cover. ( ð 12-5) Remove the two bolts attaching the air cleaner case. Loosen the band between the air cleaner and carburetor to remove the air cleaner case.
  • Page 54 . ENGINE REMOVAL/INSTALLATION ZX / SCOUT Remove the rear brake adjusting nut and disconnect the brake cable from the crankcase. Remove the rear brake cable clamp and rear brake cable. Remove the cooling air tube band on the left crankcase cover and disconnect the cooling air tube.

  • Page 55: Engine Installation

    ZX / SCOUT . ENGINE REMOVAL/INSTALLATION Inspect the stopper rubbers and bushings for damage and replace with new ones if necessary. Bushings Stopper Rubbers ENGINE INSTALLATION Install the engine in the reverse order of removal. Cables and wires should be routed properly.

  • Page 56: Cylinder Head/Cylinder/Piston

    ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/CYLINDER/PISTON __________________________________________________________________________________ SERVICE INFORMATION............6-2 TROUBLESHOOTING ..............6-2 CYLINDER HEAD ................. 6-3 CYLINDER/PISTON..............6-6...
  • Page 57 ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON Torque: 1.5 1.7kg-m Torque: 1.1 1.7kg-m (cold)

  • Page 58: Service Information

    ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head, cylinder and piston can be serviced with the engine installed in the frame. • Before disassembly, clean the engine to prevent dust from entering the engine.

  • Page 59: Cylinder Head

    ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON CYLINDER HEAD REMOVAL Remove the rear carrier. Remove the frame body cover. ( ð 12-5) Fan Cover/Engine Hood Remove the spark plug cap. Remove the three bolts attaching the fan cover to remove the fan cover.
  • Page 60 ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON DECABONIZING Remove the carbon deposits from the combustion chamber Avoid damaging the combustion cham-ber wall and cylinder mating surface. Mating Surface CYLINDER HEAD INSPECTION Check the cylinder head for warpage with a straight edge and feeler gauge.
  • Page 61 ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON Cylinder Head Bolts Installation Install and tighten the cylinder head bolts diagonally in 2 or 3 times. Torque: 1.5 1.7kg-m Install the spark plug. Torque: 1.1 1.7kg-m Cylinder Head Spark Plug Spark Plug Engine Hood Engine Hood Installation Install the engine hood.

  • Page 62: Cylinder/Piston

    ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON CYLINDER/PISTON CYLINDER REMOVAL Remove the met-in box and seat. Remove the frame body cover. Remove the cylinder head. Remove the two exhaust muffler joint lock nuts and two exhaust muffler lock bolts. Remove the exhaust muffler.
  • Page 63 ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON CYLINDER/PISTON INSPECTION Check the cylinder and piston for wear or damage. Clean carbon deposits from the exhaust port area. Be careful not to damage the cylinder inside wall. Measure the cylinder bore at three levels of A, B and C in both X and Y directions.
  • Page 64 ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON A Mark Nuts Measure the piston O.D. at a point 5mm from the bottom of the piston skirt. Service Limit: 38.90mm replace if below Measure the piston-to-cylinder clearance. Service Limit: 0.10mm replace if over Measure the piston pin hole I.D.
  • Page 65 ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON Measure each piston ring end gap. Service Limits: Top/Second 0.40mm replace if over Set each piston ring squarely into the cylinder using the piston and measure the end gap. CONNECTING ROD SMALL END INSPECTION...
  • Page 66 ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON Cylinder Gasket Ring Pins Make sure that the ring end gaps are aligned with the piston ring pins in the ring grooves. Lubricate the cylinder inside and piston rings with engine oil and install the piston into the cylinder while compressing the piston rings.

  • Page 67: A.c. Generator

    ZX / SCOUT . A.C. GENERATOR __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ A.C. GENERATOR __________________________________________________________________________________ SERVICE INFORMATION............7-2 A.C. GENERATOR REMOVAL............. 7-3 A.C. GENERATOR INSTALLATION..........7-4...
  • Page 68 ZX / SCOUT . A.C. GENERATOR Torque: 0.8 1.2kg-m Torque: 3.5 4.0kg-m Torque: 0.6 1.0kg-m Torque: 0.8 1.2kg-m...
  • Page 69 ZX / SCOUT . A.C. GENERATOR SERVICE INFORMATION GENERAL INSTRUCTIONS • All A.C. generator maintenance and inspection can be made with the engine installed. • Refer to Section 15 for A.C. generator inspection. TORQUE VALUE Flywheel nut : 3.5 4.0kg-m...
  • Page 70 ZX / SCOUT . A.C. GENERATOR remove the fan cover. Fan Cover Bolt Remove the cooling fan by removing the four bolts. Cooling Fan Hold the flywheel with an universal holder and then remove the flywheel nut. Universal Holder Bolts Remove the A.C.
  • Page 71 ZX / SCOUT . A.C. GENERATOR Flywheel Puller Remove the A.C. generator wire connector. A.C. Generator Wire Connector Remove the two pulser coil bolts and pulser Stator Wire Clamp coil from the right crankcase. Remove the pulser coil wire clamp from the right crankcase.
  • Page 72 ZX / SCOUT . A.C. GENERATOR Woodruff Key Clean the taper hole in the flywheel off any burrs and dirt. Install the woodruff key in the crankshaft keyway. Install the flywheel onto the crankshaft with the flywheel groove aligned with the crankshaft woodruff key.

  • Page 73: Kick Starter/Drive Pulley/Clutch/Driven Pulley

    . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY __________________________________________________________________________________ SERVICE INFORMATION............8- 2 TROUBLESHOOTING ..............8- 2 KICK STARTER................8- 3 DRIVE BELT ................. 8- 7 DRIVE PULLEY................8- 9 STARTER PINION ................
  • Page 74 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY MODEL SC10AS Torque: 5.0 6.0kg-m Torque: 3.5 4.5kg-m...
  • Page 75 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY SERVICE INFORMATION GENERAL INSTRUCTIONS • Avoid getting grease and oil on the drive belt and pulley faces. SPECIFICATIONS SC10AS Item Standard (mm) Service Limit (mm) Drive pulley collar O.D. 20.01 20.025 24.24...
  • Page 76 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Remove the drive belt cooling air tube connector circlip. Remove the nine left crankcase cover bolts, left crankcase cover and dowel pins. Inspect the left crankcase cover seal rubber for damage or deterioration.
  • Page 77 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Spindle Return Spring KICK STARTER SPINDLE INSPECTION Inspect the kick starter spindle and gear for wear or damage. Inspect the return spring for weakness or damage. Inspect the kick starter spindle bushing for wear or damage.
  • Page 78 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Kick Starter Driven Gear Forcing Part KICK STARTER INSTALLATION Install the kick starter spindle bushing and return spring onto the left crankcase cover. If the hooks of the return spring can not be installed properly, use a screw driver to press them into their locations respectively.

  • Page 79: Drive Belt

    . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Washer Circlip Dowel Pins LEFT CRANKCASE COVER INSTALLATION First install the dowel pins and then the seal rubber. Left Crankcase Cover Install the left crankcase cover and tighten the nine bolts diagonally.
  • Page 80 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Measure the drive belt width. Service Limit: 16.5mm replace if below Use specified genuine parts for replace-ment. Clutch Outer Clutch Outer Nut REPLACEMENT Remove the nine left crankcase cover bolts and left crankcase cover. ( ð 8-3)
  • Page 81 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Drive Belt DRIVE BELT INSTALLATION Turn the driven pulley clockwise and lift it up to expand the drive belt groove and then install a new drive belt. Drive Belt Drive Face Nut...
  • Page 82 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Drive Face Nut Movable Drive Face MOVABLE DRIVE FACE DISASSEMBLY Remove the movable drive face and drive pulley collar from the crankshaft. Drive Pulley Collar Ramp Plate Remove the ramp plate.
  • Page 83 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY MOVABLE DRIVE FACE INSPECTION Check each weight roller for wear or damage. Measure each roller O.D. Service Limit: 12.4mm replace if below Movable Drive Face DRIVE PULLEY INSTALLATION Install the drive pulley collar and movable drive face onto the crankshaft.
  • Page 84 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Drive Face Nut Starting Ratchet STARTER PINION REMOVAL Remove the left crankcase cover. ( ð 8-3) Remove the drive pulley. ( ð 8-9) Remove the starter pinion. Starter Pinion Shaft Forcing Parts INSPECTION Inspect the starter pinion seat for wear.
  • Page 85 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Universal Holder Clutch/Driven Pulley Remove the clutch/driven pulley. Remove the drive belt from the clutch/driven pulley. Lock Nut Wrench, 39mm CLUTCH/DRIVEN PULLEY DIS-ASSEMBLY Compress the clutch/driven pulley spring with the clutch spring compressor and remove the 39mm drive plate nut.
  • Page 86 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Pull out the guide roller pins from the driven pulley and then remove the O-rings and oil seal from the driven pulley. CLUTCH/DRIVEN PULLEY INSPECTION Inspect the clutch outer for wear or damage.
  • Page 87 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Measure the driven face spring free length. Service Limit: 82.6mm replace if below Check the driven face assembly for wear or damage. Measure the driven face O.D. Service Limit: 33.94mm replace if below Check the movable driven face for wear or damage.
  • Page 88 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Snap Ring Remove the snap ring and drive the outer bearing out of the driven face. Outer Bearing Bearing Outer Driver, 37x40mm Drive a new outer bearing into the driven face with the sealed end facing up.
  • Page 89 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Outer Driver, 24x26mm Driven Pulley Oil Seal CLUTCH/DRIVEN PULLEY ASSEMBLY First install the movable driven face onto the driven face. Then, install the guide roller pins, O-rings and a new oil seal.
  • Page 90 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Clutch/Driven Pulley CLUTCH/DRIVEN PULLEY INSTALLATION Install the drive belt on the clutch/driven pulley and then install the clutch/driven pulley onto the drive shaft. Clutch Outer Install the clutch outer. Hold the clutch outer with the universal holder.

  • Page 91: Final Reduction

    . FINAL REDUCTION ZX / SCOUT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SERVICE INFORMATION............9-2 TROUBLESHOOTING ..............9-2 FINAL REDUCTION DISASSEMBLY........... 9-3 FINAL REDUCTION INSPECTION ..........9-3 FINAL REDUCTION ASSEMBLY..........9-6...
  • Page 92 . FINAL REDUCTION ZX / SCOUT...
  • Page 93 ZX / SCOUT . FINAL REDUCTION SERVICE INFORMATION Specified Oil: SAE90# At disassembly: 0.12 liter At change: 0.1 liter SPECIAL TOOLS Bearing remover set, 12mm Bearing remover set, 15mm Crankcase assembly collar Crankcase assembly shaft Bearing outer driver, 37x40mm Bearing outer driver, 32x35mm...
  • Page 94 . FINAL REDUCTION ZX / SCOUT DISAS-SEMBLY Remove the rear wheel. ( ð 14-3) Remove the left crankcase cover. ( ð 8-3) Remove the clutch/driven pulley. ( ð 8-7) Drain the transmission gear oil into a clean container. Remove the transmission case cover attaching bolts.
  • Page 95 ZX / SCOUT . FINAL REDUCTION damage or seizure. Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage. Final Shaft Inspect the drive shaft and gear for wear or Drive Shaft Bearing Oil Seal damage.
  • Page 96 . FINAL REDUCTION ZX / SCOUT Case Cover) Remove the transmission case cover bearings using the bearing remover. Remove the final shaft oil seal. Bearing Remover Set Bearing Outer Driver Handle A Drive new bearings into the transmission case cover.
  • Page 97 ZX / SCOUT . FINAL REDUCTION Install a new drive shaft oil seal. Bearing Outer Driver FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase. Drive Shaft Install the final gear and final shaft into the left crankcase.
  • Page 98 . FINAL REDUCTION ZX / SCOUT crankcase. Install the resin washer onto the counter-shaft. Install the dowel pins and a new gasket. Countershaft Resin Washer Install the transmission case cover. Transmission Case Cover Install and tighten the transmission case cover bolts.
  • Page 99 ZX / SCOUT . FINAL REDUCTION • Place the motorcycle on its main stand on level ground. • Check the sealing washer for wear or damage. Specified Gear Oil: SAE90# Oil Capacity: at disassembly: 0.12 liter at change: 0.1 liter Install and tighten the oil check bolt.

  • Page 100: Crankcase/Crankshaft

    . CRANKCASE/CRANKSHAFT ZX / SCOUT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE/CRANKSHAFT __________________________________________________________________________________ SERVICE INFORMATION............10-2 TROUBLESHOOTING ..............10-2 CRANKCASE SEPARATION............10-3 CRANKSHAFT REMOVAL............10-3 CRANKSHAFT INSPECTION............10-4 CRANKSHAFT INSTALLATION..........10-5 CRANKCASE ASSEMBLY............10-7 10-0...
  • Page 101 . CRANKCASE/CRANKSHAFT ZX / SCOUT Torque: 0.8 1.2kg-m 10-1...

  • Page 102: Service Information

    ZX / SCOUT . CRANKCASE/CRANKSHAFT SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. • The following parts must be removed before separating the crankcase. Engine ( ð Section 5) Driven pulley ( ð Section 8) Carburetor ( ð...

  • Page 103: Crankcase Separation

    . CRANKCASE/CRANKSHAFT ZX / SCOUT CRANKCASE SEPARATION Remove the crankcase attaching bolts. Crankcase Puller Attach the crankcase puller on the right crankcase and remove the right crankcase from the left crankcase. Crankcase Puller CRANKSHAFT REMOVAL Attach the crankcase puller on the left crankcase and remove the crankshaft from the left crankcase.

  • Page 104: Crankshaft Inspection

    ZX / SCOUT . CRANKCASE/CRANKSHAFT Remove the remaining bearing on the crankshaft side using the universal bearing puller. Universal Bearing Puller CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance. Service Limit: 0.6mm replace if over Measure the connecting rod big end radial clearance at two points in the X and Y directions.

  • Page 105: Crankshaft Installation

    . CRANKCASE/CRANKSHAFT ZX / SCOUT Service Limit 0.150mm 0.100mm replace if over replace if over Play Check the crankshaft bearings for excessive play. The bearings must be replaced if they are noisy or have excessive play. Play Axial Radial CRANKSHAFT INSTALLATION Wash the crankshaft in cleaning solvent and then check for cracks or other faults.

  • Page 106: Crankcase Assembly

    ZX / SCOUT . CRANKCASE/CRANKSHAFT Bearing Outer Driver, 37x40mm Bearing Driver Pilot, 17mm Bearing Outer Driver Handle A Drive a new crankshaft bearing into the left crankcase. Bearing Outer Driver, 42x47mm Pilot, 20mm Crankcase Assembly Collar Install the crankshaft into the left crankcase.
  • Page 107 . CRANKCASE/CRANKSHAFT ZX / SCOUT crankcase mating surface. Assemble the crankcase halves. Crankcase Assembly Tool The distance between the right crankcase oil seal and crankcase surface is about 12.5±0.5 Crankcase Assembly Tool Dowel Pins The distance between the left crankcase oil seal and crankcase surface is about 1.0mm.
  • Page 108 ZX / SCOUT . CRANKCASE/CRANKSHAFT 1.0mm Install and tighten the crankcase attaching bolts. Oil Seal 10-8...

  • Page 109: Carburetor

    . CARBURETOR ZX / SCOUT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CARBURETOR __________________________________________________________________________________ SERVICE INFORMATION............11- 2 TROUBLESHOOTING ..............11- 2 THROTTLE VALVE DISASSEMBLY ........... 11- 3 THROTTLE VALVE INSTALLATION.......... 11- 4 CARBURETOR REMOVAL ............11- 5 AUTO BYSTARTER ..............11- 6 FLOAT CHAMBER ...............
  • Page 110 . CARBURETOR ZX / SCOUT 11-1...

  • Page 111: Service Information

    ZX / SCOUT . CARBURETOR SERVICE INFORMATION GENERAL INSTRUCTIONS When working with gasoline, keep away from sparks and flames.. • Note the locations of O-rings when disassembling and replace them with new ones during • assembly. All cables, fuel lines and wires must be routed and secured at correct locations.

  • Page 112: Throttle Valve Disassembly

    . CARBURETOR ZX / SCOUT THROTTLE VALVE DIS-ASSEMBLY Remove the rear carrier. ( ð 12-5) Remove the met-in box. ( ð 12-4) Loosen the carburetor cap and remove the throttle valve. Carburetor Cap Throttle Valve Disconnect the throttle cable from the throttle valve.

  • Page 113: Throttle Valve Installation

    ZX / SCOUT . CARBURETOR Remove the jet needle by removing the needle clip. Needle Clip Check the jet needle and throttle valve for wear or damage. Needle Retainer 2nd Notch (STD) Jet Needle Throttle Valve Rubber Seal Carburetor Cap...

  • Page 114: Carburetor Removal

    . CARBURETOR ZX / SCOUT the throttle valve with the throttle stop screw. Throttle Stop Screw Carburetor Cap Tighten the carburetor cap. After installation, perform the following adjustments and inspections. • Throttle cable free play ( ð 3-11) • Idle speed adjustment ( ð 3-8) Install the met-in box.

  • Page 115: Auto Bystarter

    ZX / SCOUT . CARBURETOR AUTO BYSTARTER AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals. Resistance: 5Ω (10 minutes minimum after stopping the engine) If the resistance exceeds 5Ω, replace the auto bystarter with a new one.
  • Page 116 . CARBURETOR ZX / SCOUT blow the hose with mouth. If air can be blown into the hose, the auto bystarter is faulty and replace it with a new one. Auto Bystarter AUTO BYSTARTER REMOVAL Remove the auto bystarter cover.

  • Page 117: Float Chamber

    ZX / SCOUT . CARBURETOR Set Plate Screws FLOAT CHAMBER Remove the two float chamber screws and the float chamber. Float Pin O-ring Remove the screw and O-ring. Remove the float pin, float and float valve. Float FLOAT/FLOAT VALVE INSPECTION...
  • Page 118 . CARBURETOR ZX / SCOUT Float Seat Main Jet JETS/SCREWS REMOVAL Before removing the throttle stop screw or air screw, record the number of rotations until it seats lightly. Then, remove them. Remove the main jet and needle jet holder.

  • Page 119: Float Level Inspection

    ZX / SCOUT . CARBURETOR Air Screw Throttle Stop Screw Install the float valve, float and float pin. Tighten the float screw securely. Float Pin FLOAT LEVEL INSPECTION Slightly tilt the carburetor and measure the float level with the float valve just connecting the float arm.

  • Page 120: Air Screw Adjustment

    . CARBURETOR ZX / SCOUT manifold and tighten the two lock nuts. Connect the fuel tube and auto bystarter wire connector. Insulator Install the carburetor cap. ( ð 11-4) Carburetor Cap Install the air cleaner onto the carburetor and tighten the band screw.

  • Page 121: Fuel Tank

    . CARBURETOR ZX / SCOUT Intake Manifold Reed Stopper INSPECTION Check the reed valve for damaged or weak reeds. Check the reed valve seat for cracks, damage or clearance between the seat and reed. Replace the valve if necessary. Reeds...
  • Page 122 . CARBURETOR ZX / SCOUT Auto Fuel Valve Fuel Tube Vacuum Tube 11-13...

  • Page 123: Frame Covers

    . FRAME COVERS ZX / SCOUT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FRAME COVERS __________________________________________________________________________________ SERVICE INFORMATION............12-2 FRAME COVERS REMOVAL............12-3 12-0...
  • Page 124 . FRAME COVERS ZX / SCOUT ASSEMBLY DRAWING 12-1...
  • Page 125 . FRAME COVERS ZX / SCOUT SERVICE INFORMATION • When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged. Items Related for Removal • Handlebar front cover Handlebar rear cover •...
  • Page 126 . FRAME COVERS Remove the bolt attaching the front cover. Remove the two screws on the back of the front cover. Remove the front cover downward. Bolt Bolt Disconnect the headlight wire connector. The installation sequence is the reverse of removal. Screw Handlebar Rear Cover During removal, be careful not to pull the...
  • Page 127 . FRAME COVERS ZX / SCOUT The installation sequence is the reverse of removal. Front Tool Box Bolt When removing the battery, first disconnect the battery negative (-) cable and then the positive (+) cable. FRONT TOOL BOX REMOVAL Remove the rear carrier. ( ð 12-5) Remove the frame body cover.
  • Page 128 . FRAME COVERS Rear Carrier FRONT FENDER REMOVAL Remove two bolts attaching each side of the front fender. Screws Screws Remove the front fender. The installation sequence is the reverse of removal. Front Fender Bolts 12-5...

  • Page 129: Steering Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Front Fork

    13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ SERVICE INFORMATION............13- 2 TROUBLESHOOTING ..............13- 2 STEERING HANDLEBAR ............. 13- 3 FRONT WHEEL ................13- 5 FRONT BRAKE (DISK BRAKE) ...........

  • Page 130: Service Information

    13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 3.3kg-m 4.5kg-m 6.0kg-m 2.7kg-m SERVICE INFORMATION 13-1...

  • Page 131: Troubleshooting

    13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SPECIFICATIONS Item Standard (mm) Service Limit (mm)  Axle shaft runout  Radial Front wheel rim runout  Axial Front brake drum I.D. Front brake lining thickness Front shock absorber spring free length 182.8...

  • Page 132: Steering Handlebar

    13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers. ( ð 12-3) Remove two bolts attaching the left brake lever holder. Remove two bolts attaching the brake master cylinder (disk brake) to the right brake lever.

  • Page 133: Front Wheel

    13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Install the handlebar, aligning the tabs of the handlebar with the grooves in the steering stem. Install and tighten the handlebar lock nut. Torque: 4.5 5.0kg-m Throttle Cable Lubricate the throttle pipe front end with grease.
  • Page 134 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK REMOVAL Jack the motorcycle front wheel off the ground. Remove the speedometer cable set screw and disconnect the speedometer cable. Remove the front axle nut and pull out the axle.
  • Page 135 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Radial: 2.0mm replace if over Axial: 2.0mm replace if over Turn the wheel bearings and replace them if Play they have excessive play or noise. Play Axial Radial DISASSEM BLY Dust Seal Remove the dust seal.
  • Page 136 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Pilot, 10mm ASSEMBLY Grease Pilot, 10mm Pack all bearing cavities with grease. Drive in the left bearing . Install the distance collar. Drive in the right bearing. Drive the bearing squarely with the sealed end facing out.
  • Page 137 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Axle Nut Groove (Disk Brake) Install the front wheel, aligning the speedometer gear tab with the front fork groove. Connect the speedometer cable. Torque: 5.0 7.0kg-m Side Collar HYDRAULIC BRAKE (FRONT BRAKE)
  • Page 138 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Check the brake fluid level on level ground. • When operating the brake lever, the brake reservoir cap must be tightened securely to avoid spill of brake fluid. • When servicing the brake system, use...
  • Page 139 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Remove the two bolts attaching the brake caliper. Remove the brake caliper. Remove the brake pad pins to remove the brake pads. Front Brake Caliper Brake Pads Install the brake pads in the reverse order of removal.
  • Page 140 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bolts Disassembly Remove the piston rubber cover and snap ring from the brake master cylinder. Master Cylinder Spring Main Piston Remove the washer, main piston and spring from the brake master cylinder.
  • Page 141 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Measure the brake master cylinder piston O.D. Service Limit: 12.6mm Before assembly, inspect the lst and 2nd rubber cups for wear. Assembly Before assembly, apply brake fluid to all removed parts.
  • Page 142 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bolts “Up” Mark Install the brake fluid pipe with the attaching bolt and two sealing washers. Install the handlebar covers. ( ð 12-3) Fill the brake reservoir with recommended brake fluid to the upper limit and bleed air according to the method stated in 13-9.
  • Page 143 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston.
  • Page 144 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Check the caliper cylinder for scratch or wear and measure the cylinder bore. Service Limit: 25.45mm Assembly Clean all removed parts. Apply silicon grease to the piston and oil seal.

  • Page 145: Front Shock Absorber

    13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bolts Connect the brake fluid pipe to the brake caliper and tighten the fluid pipe bolt. Torque: 3.0 4.0kg-m Fill the brake reservoir with recommended brake fluid and bleed air from the brake system.
  • Page 146 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Mount Bolt Front Shock Absorber Circlip LEFT FRONT SHOCK ABSORBER DISASSEMBLY Remove the dust boot. Remove the circlip. Dust Boot Use a vise to hold the front shock absorber...
  • Page 147 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Measure the front shock absorber spring free length. Service Limit: Right : 200mm Left : 200mm FRONT SHOCK ABSORBER ASSEMBLY Damper Damper Nut Dust Seal Front Shock Absorber Circlip...
  • Page 148 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Damper Nut Front Shock Absorber Use a vise to hold the front shock absorber. Tighten the hex bolt. (Apply locking agent to the washer and socket hex bolt and install them together.) Torque: 1.5 3.0kg-m...

  • Page 149: Front Fork

    13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Front Shock Absorber FRONT FORK REMOVAL Remove the steering handlebar. ( ð 13-3) Disconnect the speedometer cable and front brake fluid pipe and remove the front brake caliper. Remove the front wheel. ( ð 13-5) Hold the steering stem top cone race and remove the steering stem lock nut.
  • Page 150 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bottom Cone Race Ball Race Remover BALL RACE REPLACEMENT Drive out the ball races. Outer Driver, 37x40mm Driver Handle A Drive in new ball races. Be sure to drive the ball races into place completely.
  • Page 151 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Apply grease to the top cone race and install it. Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely.

  • Page 152: Rear Wheel/Rear Brake/Rear Shock Absorber

    . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER __________________________________________________________________________________ SERVICE INFORMATION............14-2 TROUBLESHOOTING ..............14-2 REAR WHEEL................14-3 REAR BRAKE ................14-4 REAR SHOCK ABSORBER ............14-7 14-0...
  • Page 153 . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER 4.5kg-m 3.0kg-m 11.0kg-m 14-1...

  • Page 154: Service Information

    . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER SERVICE INFORMATION SPECIFICATIONS Item Standard (mm) Service Limit (mm) Rear wheel rim runout Rear brake drum I.D. Rear brake lining thickness Rear shock absorber spring free length 235.7 218.7 TORQUE VALUES Rear axle nut 11.0 13.0kg-m...

  • Page 155: Shock Absorber

    . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER Remove the two exhaust muffler joint lock nuts. Remove the two exhaust muffler lock bolts. Remove the exhaust muffler. Remove the rear axle nut to remove the rear wheel. INSPECTION Measure the rear wheel rim runout.
  • Page 156 . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER Inspect the rear brake drum. Measure the rear brake drum I.D. Service Limit: 95.5mm replace if over BRAKE LINING INSPECTION Measure the brake lining thickness. Service Limit: 2.0mm replace if below Keep oil or grease off the brake linings.
  • Page 157 . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER Brake Arm Brake Cam Grease REAR BRAKE ASSEMBLY Apply grease to the anchor pin and brake shoe moving parts. Apply grease to the brake cam and install it. Apply engine oil to the felt seal and install it to the brake cam.
  • Page 158 . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER Adjust the rear brake lever free play. ( ð 3-4) Adjusting Nut Brake Arm Pin Brake Arm REAR SHOCK ABSORBER REMOVAL Remove the rear carrier. ( ð 12-5) 14-6...

  • Page 159: Rear Shock Absorber

    . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER Remove the met-in box. ( ð 12-4) Remove the air cleaner case. ( ð 5-2) Remove the rear shock absorber upper and lower mount bolts to remove the rear shock absorber.
  • Page 160 . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER Inspect the damper rubber for deterioration or damage. Damper Rubber Damper Rod Measure the rear shock absorber spring free length. Service Limit: 232mm replace if below ASSEMBLY Assemble the rear shock absorber in the reverse order of disassembly.
  • Page 161 . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER Torque: Upper Mount Bolt: 3.5 4.5kg-m Lower Mount Bolt: 2.4 3.0kg-m Install the frame body cover. ( ð 12-5) Lower Mount Bolt Upper Mount Bolt 14-9...

  • Page 162: Electrical Equipment

    . ELECTRICAL EQUIPMENT ZX / SCOUT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ELECTRICAL EQUIPMENT __________________________________________________________________________________ SERVICE INFORMATION............15- 1 TROUBLESHOOTING ..............15- 1 CHARGING SYSTEM ..............15- 3 BATTERY..................15- 4 IGNITION SYSTEM ..............15- 7 STARTING SYSTEM ..............15-11 15-0...

  • Page 163: Service Information

    ZX / SCOUT . ELECTRICAL EQUIPMENT SERVICE INFORMATION GENERAL INSTRUCTIONS • It is not necessary to check the battery electrolyte or fill with distilled water. • Remove the battery from the motorcycle for charging. Do not remove the electrolyte cap..
  • Page 164 . ELECTRICAL EQUIPMENT ZX / SCOUT IGNITION SYSTEM No spark at plug Engine starts but turns poorly • Faulty spark plug • Ignition primary circuit • Poorly connected, broken or shorted wire —Faulty ignition coil —Between A.C. generator and CDI unit —Poorly connected wire or connector...
  • Page 165 ZX / SCOUT . ELECTRICAL EQUIPMENT CHARGING SYSTEM Dimmer Switch Headlight Switch Ignition Switch Resistor Regulator/Rectifier Battery A.C. Generator 15-3...

  • Page 166: Battery

    . ELECTRICAL EQUIPMENT ZX / SCOUT BATTERY BATTERY REMOVAL Remove the battery cover. Disconnect the battery cables . Remove the bolt and battery bracket. Remove the battery. The installation sequence is the reverse of removal. BATTERY CHARGING (OPEN CIRCUIT VOLTAGE) INSPECTION Remove the battery cover and disconnect the battery cables.
  • Page 167 ZX / SCOUT . ELECTRICAL EQUIPMENT Warm up the engine. Remove the floor mat and battery cover. Stop the engine and open the fuse box. Disconnect the wire lead from the fuse terminal. Connect an ammeter between the wire lead and fuse terminal as shown.
  • Page 168 . ELECTRICAL EQUIPMENT ZX / SCOUT wire and ground. Measure the resistance between the resistor A green/black wire and ground. Resistances: Resistor A: 9.9 10.5Ω Resistor B: 5.6 6.2Ω REGULATOR/RECTIFIER INSPECTION Remove the front cover. ( ð 12-3) Resister A...

  • Page 169: Ignition System

    ZX / SCOUT . ELECTRICAL EQUIPMENT IGNITION SYSTEM Ignition Coil Ignition Switch CDI Unit Pulser Coil A.C. Generator (Exciter Coil) Pulser Coil IGNITION COIL INSPECTION Continuity Test 15-7...
  • Page 170 . ELECTRICAL EQUIPMENT ZX / SCOUT Remove the met-in box. ( ð 12-4) Measure the resistance between the ignition coil primary coil terminals. Resistance (20 ): 0.153 0.187Ω Measure the secondary coil resistance between the spark plug cap and the primary coil terminal as Figure A shown.
  • Page 171 ZX / SCOUT . ELECTRICAL EQUIPMENT Exciter Coil/Pulser Coil Inspection Remove the met-in box. ( ð 12-4) Disconnect the A.C. generator wire connector. Measure the pulser coil resistance between the blue/yellow wire and ground. Resistance (20 ): 80 160Ω Blue/Yellow CDI UNIT INSPECTION Remove the battery cover.
  • Page 172 . ELECTRICAL EQUIPMENT ZX / SCOUT unit. CDI CIRCUIT INSPECTION Measure the resistance between the terminals. CDI Unit Replace the CDI unit if the readings are not within the specifications in the table below. Black/ Black/ Black/ White Yellow Use the KΩ...

  • Page 173: Starting System

    ZX / SCOUT . ELECTRICAL EQUIPMENT Starting System Starter Button Starter Button Ignition Switch Battery Starter Relay Starter Relay Starter Button Starter Morter INSPECTION Remove the battery cover. STARTER RELAY Disconnect the starter relay coupler and then 15-11...

  • Page 174: Starter Motor Removal

    . ELECTRICAL EQUIPMENT ZX / SCOUT remove the starter relay. Yellow/Red Connect the starter relay green/yellow terminal to the 12V battery positive (+) terminal and the relay yellow/red terminal to the battery negative (-) terminal. Check for continuity between the starter relay red and red/white terminals.
  • Page 175 ZX / SCOUT . ELECTRICAL EQUIPMENT Battery 15-13...

  • Page 176: Instrument/Switches/Lights

    . INSTRUMENT/SWITCHES/LIGHTS ZX / SCOUT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSTRUMENT/SWITCHES/LIGHTS __________________________________________________________________________________ SERVICE INFORMATION............16-1 TROUBLESHOOTING ..............16-1 FUEL UNIT..................16-2 OIL METER ................... 16-3 SWITCHES..................16-5 STOP SWITCH INSPECTION/HORN........... 16-6 BULB REPLACEMENT ..............16-7 INSTRUMENT/HEADLIGHT............16-8 16-0...

  • Page 177: Service Information

    . INSTRUMENT/SWITCHES/LIGHTS ZX / SCOUT SERVICE INFORMATION GENERAL INSTRUCTIONS • Wires should be connected to other wires of the same color. Couplers must be connected to other couplers of the same color. • All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting.

  • Page 178: Fuel Unit

    ZX / SCOUT . INSTRUMENT/SWITCHES/LIGHTS Fuel Unit FUEL UNIT REMOVAL Remove the frame body cover. ( ð 12-5) Disconnect the fuel unit wire connectors. Turn the fuel unit retainer counterclockwise to remove it. Remove the fuel unit. Fuel Unit Wire INSPECTION Remove the fuel unit.

  • Page 179: Oil Meter

    . INSTRUMENT/SWITCHES/LIGHTS ZX / SCOUT INSTALLATION The installation sequence is the reverse of removal. Retainer OIL METER Oil Meter INSPECTION Remove the met-in box. ( ð 12-4) Remove the frame body cover. ( ð 12-4) Disconnect the oil meter wire connectors and remove the oil meter.

  • Page 180: Switches

    ZX / SCOUT . INSTRUMENT/SWITCHES/LIGHTS Move the oil meter float up and down to see if the oil indicator light will go out and come on. SWITCHES IGNITION SWITCH INSPECTION Remove the front cover. ( ð 12-3) Disconnect the ignition switch wire couplers and check for continuity between the wire terminals.
  • Page 181 . INSTRUMENT/SWITCHES/LIGHTS ZX / SCOUT Remove the handlebar rear cover. ( ð 12-3) Disconnect the headlight switch wire coupler and check for continuity between wire terminals. Color Blue/White Yellow Brown Pink Brown/White Symbol Br/W Headlight Switch DIMMER SWITCH INSPECTION Check for continuity between wire terminals.

  • Page 182: Stop Switch Inspection/Horn

    ZX / SCOUT . INSTRUMENT/SWITCHES/LIGHTS Push the starter button when measuring. Color Yellow/Red Green Symbol FREE PUSH Starter Switch HORN SWITCH INSPECTION Check for continuity between wire terminals. Push the horn button when measuring. Color Light Green Black Symbol FREE...

  • Page 183: Bulb Replacement

    . INSTRUMENT/SWITCHES/LIGHTS ZX / SCOUT connected across the horn wire terminals. FRONT TURN SIGNAL LIGHT REPLACEMENT Remove the turn signal light shell and the bulb. Replace with new ones. Turn Signal Light Bulb Taillight Shell TAILLIGHT/STOPLIGHT/REAR TURN SIGNAL LIGHT BULB...
  • Page 184 ZX / SCOUT . INSTRUMENT/SWITCHES/LIGHTS Bulb Sockets Speedometer cable SPEEDOMETER REMOVAL Disconnect the speedometer cable. Disconnect the speedometer wire connector. Remove the three screws attaching the speedometer. Remove the speedometer. The installation sequence is the reverse of removal. Bulb Sockets...

  • Page 185: Evaporative/Exhaust Emission Contral System

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM ZX / SCOUT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM __________________________________________________________________________________ EXHAUST EMISSION CONTROL SYSTEM ........ 17- 1 EXHAUST MUFFLER ..............17- 2 EXHAUST EMISSION RELATED SYSTEM INSPECTION ..17-3 17-0...

  • Page 186: Exhaust Emission Control System

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM ZX / SCOUT EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system adopted by this model is an oxidizing catalytic converter which is located in the middle of the exhaust muffler to reduce pollutants in the exhaust emission.
  • Page 187 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM ZX / SCOUT Remove the two exhaust muffler joint lock nuts and two exhaust muffler lock bolts. Remove the exhaust muffler. • The temperature of exhaust muffler is very high. Be careful to avoid burns during working.
  • Page 188 ZX 50 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM ZX 50 EXHAUST EMISSION RELATED SYSTEM INSPECTION Clean or replace the air cleaner. Clean and adjust the carburetor. Inspect the auto bystarter system. Clean and inspect the spark plug. Inspect the ignition system.

This manual is also suitable for:

Scout 50

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