KYMCO ZX/SCOUT 50 Service Manual
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KYMCO ZX/SCOUT 50 Service Manual

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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.
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.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
MARCH 2000

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Summary of Contents for KYMCO ZX/SCOUT 50

  • 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 CARBURETOR....................11 FRAME COVERS...................12 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/FRONT FORK ...........13...

  • Page 3: Specifications

    SPECIFICATIONS ZX 50 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 ⎯ Wheel base (mm) 1225 Carburetor Piston dia.

  • 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 SERVICE PRECAUTIONS Apply or add designated greases and lubricants to the specified lubrication points. Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. When tightening bolts or nuts, begin with larger-diameter to smaller ones at several After reassembly, check all parts for proper times, and tighten to the specified torque...
  • Page 7 . GENERAL INFORMATION ZX / SCOUT If the fuse is burned out, find the cause and The connector shall be inserted repair it. Replace it with a new one completely. according to the specified capacity. If the double connector has a lock, lock it at the correct position.
  • Page 8 ZX / SCOUT . GENERAL INFORMATION After clamping, check each wire to make Route harnesses so they are neither sure it is secure. pulled tight nor have excessive slack. Do not squeeze wires against the weld or its clamp. Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner.
  • Page 9 . GENERAL INFORMATION ZX / SCOUT After routing, check that the wire harnesses are not twisted or kinked. Symbols: The following symbols represent the servicing methods and cautions included in this service manual. Wire harnesses routed along with handlebar should not be pulled tight, have : Apply engine oil to the excessive slack or interfere with adjacent specified points.

  • Page 10: Service Information

    ZX / SCOUT . GENERAL INFORMATION SERVICE INFORMATION ENGINE Standard (mm) Service Limit (mm) SC10AS SC10AS Item ⎯ 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. 12.002 12.008 12.03 Piston pin O.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. Front/rear Brake lining thickness Front/rear...

  • 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 Engine mounting bolt...

  • 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 Crankcase disassembly Bearing remover set, 12mm Drive shaft bearing removal/installation...

  • Page 14: Lubrication Points

    ZX / SCOUT . GENERAL INFORMATION LUBRICATION POINTS ENGINE Lubrication Points Lubricant Remarks Crankcase sliding & movable 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 Starter pinion movable parts Grease...

  • Page 15: Wiring Diagram

    ZX / SCOUT . GENERAL INFORMATION SC10AS WIRING DIAGRAM 2-11...

  • Page 16: Cable & Harness Routing

    ZX / SCOUT . GENERAL INFORMATION CABLE & HARNESS ROUTING 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 2-13...
  • Page 18 ZX / SCOUT . GENERAL INFORMATION Fuel Unit Ignition Coil Oil Tube CDI Unit Oil Tank Cap Wire Harness Battery Ignition Coil Fuel Filter Starter Relay 2-14...
  • Page 19 ZX / SCOUT . GENERAL INFORMATION Fuel Unit Fuel Tank Cap Vacuum Tee Oil Tube Oil Pump Ignition Coil 2-15...

  • Page 20: Troubleshooting

    ZX / SCOUT . GENERAL INFORMATION TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw. Empty fuel tank Clogged float valve Fuel does not Fuel reaches Clogged fuel filter carburetor reach carburetor...
  • Page 21 ZX / SCOUT . GENERAL INFORMATION ENGINE STOPS IMMEDIATELY AFTER IT STARTS 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 Clogged fuel filter carburetor reach carburetor Faulty auto fuel valve Remove spark plug and...
  • Page 22 ZX / SCOUT . GENERAL INFORMATION Inspection/Adjustment Symptom Probable Cause Check carburetor gasket for air leaks. Carburetor not securely tightened Air leaks No air leak Faulty intake manifold gasket 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 ENGINE LACKS POWER Inspection/Adjustment Symptom Probable Cause Start engine and accelerate lightly for observation. Clogged air cleaner Engine speed Clogged fuel filter Engine speed does Clogged exhaust muffler increases not increase Faulty auto bystarter ffi i tl Check ignition timing (using a timing light).
  • Page 24 ZX / SCOUT . GENERAL INFORMATION POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause 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)
  • Page 25 ZX / SCOUT . GENERAL INFORMATION POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing. Faulty CDI unit Correct timing Incorrect timing Loose A.C.G. stator Faulty A.C. generator Check auto fuel valve for fuel supply. Empty fuel tank Fuel flows freely Fuel flow restricted Clogged fuel tube or filter...
  • Page 26 ZX / SCOUT . GENERAL INFORMATION CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause Worn or slipping drive belt Broken ramp plate Broken driven face spring Engine starts but Separated clutch lining motor-cycle does not Damaged driven pulley shaft splines Damaged final gear Seized final gear Motorcycle creeps or...
  • Page 27 ZX / SCOUT . GENERAL INFORMATION POOR SUSPENSION PERFORMANCE Symptom Probable Cause (Front and rear tire pressures are normal) Weak shock spring Suspension is too soft Excessive load 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...
  • Page 28 ZX / SCOUT . GENERAL INFORMATION OIL METER 1. Motor oil indicator light does not come on when there is no motor oil (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn signals. Burned out fuse Weak or dead battery Signals dim, remain Signals operate...
  • Page 29 ZX / SCOUT . GENERAL INFORMATION FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn signals. Burned out fuse Weak or dead battery Signals operate Signals dim, remain Faulty ignition switch properly on or don‘t operate...
  • Page 30 ZX / SCOUT . GENERAL INFORMATION STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustment Probable Cause Check operation of Burned out fuse stop switch by Weak or dead battery applying brake. Faulty stop switch Stoplight does not Stoplight comes on Loose or disconnected come on connector...

  • 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. 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 Inspection & Maintenance Item Judgment Standards Remarks Every 6 Every 12 Preride month months months ○ ○ ○ Tire crack and damage Groove Depth: Tire groove and ○ ○ ○ Front: 0.8mm abnormal wear Rear : 0.8mm Imbedded objects, ○...
  • Page 34 ZX /SCOUT 50 . INSPECTION/ADJUSTMENT Loose connection and ○ Wires damage Frequency Inspection & Maintenance Item Judgment Standards Remarks Every 6 Every 12 Preride month months months Performance and abnormal ○ ○ noise Conditions at low and high ○ ○ ○...
  • Page 35 ZX /SCOUT 50 . INSPECTION/ADJUSTMENT ○ ○ Lubrication points Remove carbon deposits on Others ○ combustion chamber, breather hole and exhaust muffler BRAKE DRUM/SHOE Brake Shoe Wear Replace the brake shoes if the arrow on the brake arm aligns with reference mark“ ” on the brake panel when the brake is fully applied.

  • Page 36: Moving Device

    . LUBRICATION SYSTEM Brake Master Cylinder MOVING DEVICE TIRES Tire Pressure Check the tire pressure. Tire pressure should be checked when tires are cold. Tire Pressure (one rider) Front: 1.50 kg/cm² Rear: 1.75 kg/cm² Tire Size: Front: 120/70-12 Rear: 120/70-12 Axle Nut/Axle Shaft Looseness Check the front and rear axle nuts for looseness.

  • Page 37: Damping Device

    . INSPECTION/ADJUSTMENT 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. Check the entire shock absorber assembly for looseness or damage. Check the action of the rear shock absorber by compressing it several times.

  • Page 38: Electrical Equipment

    . LUBRICATION SYSTEM 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 Gap, Wear and 0.6-0.7mm Spark Plug...

  • Page 39: Engine

    . INSPECTION/ADJUSTMENT F Mark ENGINE Throttle Stop Screw 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.
  • Page 40 . LUBRICATION SYSTEM 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. Remove the oil filter.
  • Page 41 . INSPECTION/ADJUSTMENT 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...
  • Page 43 . INSPECTION/ADJUSTMENT Headlight Adjusting Bolt 3-12...

  • Page 44: Lubrication System

    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 OIL TANK ................... 4-6...
  • Page 45 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 Outlet Line Oil Pump 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. ( 12-4) Oil Inlet Line Control Cable Control Cable plate...

  • Page 48: Oil Pump Installation

    ZX /SCOUT 50 . LUBRICATION SYSTEM OIL PUMP INSTALLATION • 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 Pump Bleeding

    ZX /SCOUT 50 . LUBRICATION SYSTEM Oil Outlet Line OIL PUMP BLEEDING • 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: Oil Tank

    ZX /SCOUT 50 . LUBRICATION SYSTEM OIL TANK OIL TANK REMOVAL Remove the rear carrier. ( 12-5) Remove the frame body cover. ( 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 3.5 4.5kg-m 4.5 5.5kg-m...
  • Page 53 ZX / SCOUT . ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Air Cleaner Case Band Remove the frame body cover. ( 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 Rear Shock Absorber Lower Mount Bolt 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 ZX / SCOUT . ENGINE REMOVAL/INSTALLATION Engine Hanger ENGINE HANGER BRACKET INSPECTION 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.
  • Page 56 . ENGINE REMOVAL/INSTALLATION ZX / SCOUT...

  • Page 57: 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 58 ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON Torque: 1.5 1.7kg-m Torque: 1.1 1.7kg-m (cold)

  • Page 59: 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 60: Cylinder Head

    ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON Spark Plug Cap CYLINDER HEAD REMOVAL Remove the rear carrier. Remove the frame body cover. ( 12-5) Fan Cover/Engine Hood Remove the spark plug cap. Remove the three bolts attaching the fan cover to remove the fan cover. Remove the two joint lock nuts on the front of the exhaust muffler and then remove the two exhaust muffler lock bolts.
  • Page 61 ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON Combustion Chamber COMBUSTION CHAMBER DECABONIZING Remove the carbon deposits from the combustion chamber Avoid damaging the combustion cham-ber wall and cylinder mating Mating Surface CYLINDER HEAD INSPECTION Check the cylinder head for warpage with a straight edge and feeler gauge.
  • Page 62 ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON Cylinder head Bolts 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...

  • Page 63: Cylinder/Piston

    ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON Joint Lock Nuts Cylinder 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 64 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 65 ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON A Mark Nuts The cylinder has an A mark or no mark on it. When replacing the cylinder with a new one, use a cylinder having the same mark as the old one. Measure the piston O.D. at a point 5mm from the bottom of the piston skirt.
  • Page 66 ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON PISTON RING INSPECTION 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 Install the piston pin and bearing in the connecting rod small end and check for...
  • Page 67 ZX / SCOUT . CYLINDER HEAD/CYLINDER/PISTON Install a new cylinder gasket on the mating surface between the cylinder and crankcase. Cylinder Gasket Ring Pins Make sure that the ring end gaps are aligned with the piston ring pins in the ring grooves.

  • Page 68: 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 69 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 70 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 SPECIAL TOOLS Flywheel puller Universal holder...
  • Page 71 ZX / SCOUT . A.C. GENERATOR Bolts A.C. GENERATOR REMOVAL Remove the three bolts attaching the fan cover to 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.
  • Page 72 ZX / SCOUT . A.C. GENERATOR Lock Nut Wrench Remove the A.C. generator flywheel using the flywheel puller. Flywheel Puller A.C. Generator Wire Connector Remove the A.C. generator wire connector. Stator Wire Clamp Remove the two pulser coil bolts and pulser coil from the right crankcase.
  • Page 73 ZX / SCOUT . A.C. GENERATOR A.C. Generator Wire Connector Connect the A.C. generator wire connector. 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 74: 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 75 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY MODEL SC10AS Torque: 5.0 6.0kg-m Torque: 3.5 4.5kg-m...
  • Page 76 . 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 Standard (mm) Service Limit (mm) Item Drive pulley collar O.D. 20.01 20.025 24.24 Movable drive face I.D.
  • Page 77 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY KICK STARTER LEFT CRANKCASE COVER REMOVAL 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 78 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Kick Starter Spindle Remove the kick starter spindle and return spring from the left crankcase cover. Remove the kick starter spindle bushing. Spindle Return Spring KICK STARTER SPINDLE INSPECTION Inspect the kick starter spindle and gear for wear or damage.
  • Page 79 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Kick Starter Spindle Forcing Part Inspect the kick starter spindle and driven gear forcing parts for wear or damage. Kick Starter Driven Gear Forcing Part KICK STARTER INSTALLATION Install the kick starter spindle bushing and return spring onto the left crankcase cover.
  • Page 80 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY First install the washer and then the circlip onto the kick starter spindle. Install the kick lever. Washer Circlip Dowel Pins LEFT CRANKCASE COVER INSTALLATION First install the dowel pins and then the seal rubber.
  • Page 81 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY DRIVE BELT Remove the left crankcase cover. INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: 16.5mm replace if below Use specified genuine parts for replace-ment.
  • Page 82 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Clutch/Driven Pulley Remove the drive belt from the 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.
  • Page 83 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Drive Pulley Face Starting Ratchet DRIVE PULLEY REMOVAL Hold the drive pulley with the holder and remove the drive face nut. Remove the starting ratchet, washer and drive pulley face. Drive Face Nut Movable Drive Face MOVABLE DRIVE FACE DISASSEMBLY...
  • Page 84 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Weight Roller Remove the weight rollers. 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 85 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Drive Pulley Face Install the drive belt on the crankshaft. Install the drive face, starting ratchet and washer, then tighten the 12mm drive face nut. Torque: 3.5 4.0kg-m Keep grease or oil off the drive belt and drive pulley faces.
  • Page 86 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Clutch Outer 14mm Clutch Outer Nut CLUTCH/DRIVEN PULLEY CLUTCH/DRIVEN PULLEY REMOVAL Remove the drive pulley. ( 8-9) Hold the clutch outer with the universal holder and remove the 14mm clutch outer nut.
  • Page 87 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Remove the seal collar. 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. Measure the clutch outer I.D.
  • Page 88 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below Measure the driven face spring free length. Service Limit: 82.6mm replace if below Check the driven face assembly for wear or damage.
  • Page 89 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY DRIVEN PULLEY FACE BEARING REPLACEMENT Check the needle bearings in the driven face and replace them if they have excessive play, damage or abnormal noise. Drive the inner bearing out of the driven pulley face.
  • Page 90 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Drive in a new needle bearing into the Bearing Driver Pilot driven face with the mark facing up. Outer Driver, 24x26mm Driven Pulley Oil Seal CLUTCH/DRIVEN PULLEY ASSEMBLY First install the movable driven face onto the driven face.
  • Page 91 . KICK STARTER/DRIVE PULLEY/ ZX / SCOUT CLUTCH/DRIVEN PULLEY Set the driven pulley, driven face spring and clutch assembly onto the clutch spring compressor. Compress the tool and install the 39mm drive plate nut. Tighten the 39mm nut to the specified torque.

  • Page 92: 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 93 . FINAL REDUCTION ZX / SCOUT...

  • Page 94: Service Information

    . FINAL REDUCTION ZX / SCOUT 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 Bearing driver pilot, 17mm Bearing driver pilot, 15mm Bearing driver pilot, 12mm...

  • Page 95: Final Reduction Disassembly

    . FINAL REDUCTION ZX / SCOUT Bolts FINAL REDUCTION DISAS-SEMBLY Remove the rear wheel. ( 14-3) Remove the left crankcase cover. ( 8-3) Remove the clutch/driven pulley. ( 8-7) Drain the transmission gear oil into a clean container. Remove the transmission case cover attaching bolts.
  • Page 96 . FINAL REDUCTION ZX / SCOUT Inspect the final gear and final shaft for wear, damage or seizure. Final Shaft Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage. Drive Shaft Bearing Oil Seal Inspect the drive shaft and gear for wear or damage.
  • Page 97 . FINAL REDUCTION ZX / SCOUT Drive Shaft Bearing BEARING REPLACEMENT (Transmission 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 98 . FINAL REDUCTION ZX / SCOUT Drive new bearings into the left crankcase. 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 99 . FINAL REDUCTION ZX / SCOUT Dowel Pins Install the countershaft and gear into the left 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 100 . FINAL REDUCTION ZX / SCOUT After installation, fill the transmission case with the specified oil. • 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 101: 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 102 . CRANKCASE/CRANKSHAFT ZX / SCOUT Torque: 0.8 1.2kg-m 10-1...

  • Page 103: Service Information

    . CRANKCASE/CRANKSHAFT ZX / SCOUT SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. • The following parts must be removed before separating the crankcase. Engine ( Section 5) Driven pulley ( Section 8) Carburetor ( Section 11) A.C.

  • Page 104: 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 105: Crankshaft Inspection

    . CRANKCASE/CRANKSHAFT ZX / SCOUT 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 106: Crankshaft Installation

    . CRANKCASE/CRANKSHAFT ZX / SCOUT Measure the crankshaft runout. 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 Play they are noisy or have excessive play. Axial Radial CRANKSHAFT INSTALLATION...
  • Page 107 . CRANKCASE/CRANKSHAFT ZX / SCOUT Drive a new crankshaft bearing into the Bearing Outer Driver Handle A right crankcase. Bearing Outer Driver, 37x40mm Bearing Driver Pilot, 17mm Drive a new crankshaft bearing into the left Bearing Outer Driver Handle A crankcase.

  • Page 108: Crankcase Assembly

    . CRANKCASE/CRANKSHAFT ZX / SCOUT Dowel Pins CRANKCASE ASSEMBLY Install the dowel pins and a new gasket to the 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 mm.
  • Page 109 . CRANKCASE/CRANKSHAFT ZX / SCOUT Oil Seal The distance between the left crankcase oil seal and crankcase surface is about 1.0mm. 1.0mm Bolts Install and tighten the crankcase attaching bolts. 10-8...

  • Page 110: 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 111 . CARBURETOR ZX / SCOUT 11-1...

  • Page 112: Service Information

    . CARBURETOR ZX / SCOUT 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 113: Throttle Valve Disassembly

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

  • Page 114: Throttle Valve Installation

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

  • Page 115: Carburetor Removal

    . CARBURETOR ZX / SCOUT Groove Install the throttle valve by aligning the groove in 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. •...

  • Page 116: Auto Bystarter

    . CARBURETOR ZX / SCOUT Bolts Remove the 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. After the engine stops for 30 minutes, connect a hose to the fuel enriching circuit and blow the hose with mouth.
  • Page 117 . CARBURETOR ZX / SCOUT Connect the auto bystarter yellow wire to the battery positive (+) terminal and green/ black wire to the battery negative (-) terminal and wait 5 minutes. Connect a hose to the fuel enriching circuit and 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.

  • Page 118: Float Chamber

    . CARBURETOR ZX / SCOUT Screws Auto Bystarter AUTO BYSTARTER INSTALLATION Install the auto bystarter into the carburetor body until it bottoms.. Install the set plate and then tighten the two screws. Set Plate Screws FLOAT CHAMBER Remove the two float chamber screws and the float chamber.
  • Page 119 . CARBURETOR ZX / SCOUT Float Valve FLOAT/FLOAT VALVE INSPECTION Inspect the float for damage or fuel inside the float. Check the float valve seat for wear or damage. 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.

  • Page 120: Float Level Inspection

    . CARBURETOR ZX / SCOUT Main Jet FLOAT CHAMBER ASSEMBLY Install the main jet and needle jet holder. Install the air screw and throttle stop screw according to the rotations recorded. Air Screw Throttle Stop Screw Install the float valve, float and float pin. Tighten the float screw securely.

  • Page 121: Carburetor Installation

    . CARBURETOR ZX / SCOUT CARBURETOR INSTALLATION Check the carburetor insulator and O-ring for wear or damage. Install the carburetor and insulator onto the intake manifold and tighten the two lock nuts. Connect the fuel tube and auto bystarter wire connector. Insulator Install the carburetor cap.

  • Page 122: Reed Valve

    . CARBURETOR ZX / SCOUT Bolts REED VALVE REMOVAL Remove the rear carrier. Remove the frame body cover. Remove the four intake manifold bolts and gasket. Remove the reed valve and gasket. Intake Manifold Reed Stopper INSPECTION Check the reed valve for damaged or weak reeds.

  • Page 123: Fuel Tank

    . CARBURETOR ZX / SCOUT FUEL TANK Fuel Unit REMOVAL Remove the met-in box. ( 12-4) Remove the frame body cover. ( 12-5) Remove the rear carrier. ( 12-5) Disconnect the fuel tube and vacuum tube at the auto fuel valve. Fuel Tank Cap Disconnect the fuel unit wire connector.

  • Page 124: Frame Covers

    . FRAME COVERS ZX / SCOUT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FRAME COVERS __________________________________________________________________________________ SERVICE INFORMATION ..............12-2 FRAME COVERS REMOVAL............12-3 12-0...
  • Page 125 . FRAME COVERS ZX / SCOUT ASSEMBLY DRAWING 12-1...
  • Page 126 . 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 127 . FRAME COVERS Front Cover FRAME COVERS REMOVAL FRONT COVER REMOVAL Remove the bolt attaching the front cover. Remove the two screws on the back of the front cover. Remove the front cover downward. Disconnect the headlight wire connector. The installation sequence is the reverse of removal.
  • Page 128 . FRAME COVERS ZX / SCOUT Bolts FLOOR BOARD REMOVAL Remove the rear carrier. ( 12-5) Remove the frame body cover. ( 12-5) Remove the right and left side rails. ( 12-3) Remove the battery cover and battery. Remove the four bolts attaching the floor board to remove the floor board.
  • Page 129 . FRAME COVERS Bolts FRAME BODY COVER REMOVAL Remove the met-in box. ( 12-4) Remove the three bolts attaching the rear carrier. Remove the rear carrier. Remove the frame body cover. The installation sequence is the reverse of removal. Rear Carrier FRONT FENDER REMOVAL Remove two bolts attaching each side of the front fender.

  • Page 130: Steering Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Front Fork

    13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK ZX / SCOUT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 131: Service Information

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

  • Page 132: Troubleshooting

    13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK ZX / SCOUT 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 Brake disk thickness 35 3.8...

  • Page 133: 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. ( 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 134: 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 135 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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. Remove the front wheel.
  • Page 136 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Axial: 2.0mm replace if over Turn the wheel bearings and replace them if Play they have excessive play or noise. Play Axial Radial DISASSEMBLY Dust Seal Remove the dust seal. Remove the wheel bearings and distance collar.
  • Page 137 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 138 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) Brake Fluid Replacement/Air Bleeding Check the brake fluid level on level ground.
  • Page 139 13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Lower Limit Bleed Valve Brake Fluid Bleeding In order to avoid spill of brake fluid, connect a transparent hose to the bleed valve. Warning Brake fluid spilled on brake pads or brake disk will reduce the braking effect.
  • Page 140 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 141 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. Clean the inside of the master cylinder and brake reservoir with brake fluid.
  • Page 142 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 143 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. ( 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 144 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 145 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 146 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 147: Front Shock Absorber

    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 and remove the shock absorber tube, hex bolt and copper washer from the front shock absorber.
  • Page 148 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 Spring Oil Seal Damping...
  • Page 149 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 Specified Oil: ss#8 Oil Capacity: 61cc...

  • Page 150: Front Fork

    13. STEERING HANDLEBAR/FRONT WHEEL/FRONT ZX / SCOUT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Install the front wheel. ( 13-8) Front Shock Absorber FRONT FORK REMOVAL Remove the steering handlebar. ( 13-3) Disconnect the speedometer cable and front brake fluid pipe and remove the front brake caliper.
  • Page 151 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 152 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. Check that the steering stem rotates freely without vertical play.

  • Page 153: 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 154 . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER 4.5kg-m 3.0kg-m 11.0kg-m 14-1...

  • Page 155: Service Information

    . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER SERVICE INFORMATION SPECIFICATIONS Standard (mm) Service Limit (mm) Item Rear wheel rim runout Rear brake drum I.D. Rear brake lining thickness 235.7 218.7 Rear shock absorber spring free length TORQUE VALUES Rear axle nut 11.0 13.0kg-m Rear shock absorber upper mount bolt 3.5 4.5kg-m...

  • Page 156: Shock Absorber

    . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER Rear Axle Nut REAR WHEEL REMOVAL 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.

  • Page 157: Rear Brake

    . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER REAR BRAKE Remove the rear wheel. ( 14-3) 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 158 . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER Wear Indicator Plate Brake Arm Bolt Remove the brake arm bolt to remove the brake arm, wear indicator plate and felt seal. Remove the brake cam. Brake Arm Brake Cam Grease REAR BRAKE ASSEMBLY Apply grease to the anchor pin and brake shoe moving parts.
  • Page 159 . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER Brake Arm Install the brake arm pin. Connect the brake cable and install the adjusting nut. Install the rear wheel. ( 14-3) Adjust the rear brake lever free play. ( 3-4) Adjusting Nut Brake Arm Pin 14-6...

  • Page 160: Rear Shock Absorber

    . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER Upper Mount Bolt REAR SHOCK ABSORBER REMOVAL Remove the rear carrier. ( 12-5) Remove the met-in box. ( 12-4) Remove the air cleaner case. ( 5-2) Remove the rear shock absorber upper and lower mount bolts to remove the rear shock absorber.
  • Page 161 . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER Spring INSPECTION Inspect the damper rod for bending or damage. Inspect the damper for oil leaks. Inspect the damper rubber for deterioration or damage. Damper Rubber Damper Rod Measure the rear shock absorber spring free length.
  • Page 162 . REAR WHEEL/REAR BRAKE/REAR ZX / SCOUT SHOCK ABSORBER Upper Mount Bolt INSTALLATION Install the rear shock absorber. Install the rear shock absorber upper mount bolt and then install the lower mount bolt. Torque: Upper Mount Bolt: 3.5 4.5kg-m Lower Mount Bolt: 2.4 3.0kg-m Install the frame body cover.

  • Page 163: 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 164: Service Information

    . ELECTRICAL EQUIPMENT ZX / SCOUT 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 165 . 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 166: Battery

    . ELECTRICAL EQUIPMENT ZX / SCOUT CHARGING SYSTEM Dimmer Switch Headlight Switch Ignition Switch Resistor Regulator/Rectifier Battery A.C. Generator 15-3...
  • Page 167 . ELECTRICAL EQUIPMENT ZX / SCOUT Battery Cover 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 168 . ELECTRICAL EQUIPMENT ZX / SCOUT PERFORMANCE TEST 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. Connect the battery positive (+) terminal to the voltmeter positive (+) probe and battery negative (-) terminal to the voltmeter...
  • Page 169 . ELECTRICAL EQUIPMENT ZX / SCOUT RESISTOR INSPECTION Remove the frame front cover. ( 12-3) Measure the resistance between the resistor B pink 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...

  • Page 170: Ignition System

    . ELECTRICAL EQUIPMENT ZX / SCOUT D (Green) IGNITION SYSTEM Ignition Coil Ignition Switch CDI Unit Pulser Coil A.C. Generator (Exciter Coil) Pulser Coil 15-7...
  • Page 171 . ELECTRICAL EQUIPMENT ZX / SCOUT IGNITION COIL INSPECTION Continuity Test Remove the met-in box. ( 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 172 . ELECTRICAL EQUIPMENT ZX / SCOUT Blue/Yellow A.C. GENERATOR Exciter Coil/Pulser Coil Inspection Remove the met-in box. ( 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 15-9...
  • Page 173 . ELECTRICAL EQUIPMENT ZX / SCOUT Blue/ ∞ 3~40 80~120 10~30 Yellow ∞ ∞ Green 2~10 10~30 CDI UNIT INSPECTION Remove the battery cover. Disconnect the CDI coupler and remove the CDI unit. Coupler CDI CIRCUIT INSPECTION Measure the resistance between the terminals.

  • Page 174: Starting System

    . ELECTRICAL EQUIPMENT ZX / SCOUT Starting System Starter Button Starter Button Ignition Switch Battery Starter Relay Starter Relay Starter Button Starter Morter 15-11...
  • Page 175 . ELECTRICAL EQUIPMENT ZX / SCOUT STARTER RELAY INSPECTION Remove the battery cover. Starter Relay Disconnect the starter relay coupler and then remove the starter relay. Connect the starter relay green/yellow terminal to the 12V battery positive (+) Yellow/Red terminal and the relay yellow/red terminal to the battery negative (-) terminal.
  • Page 176 . ELECTRICAL EQUIPMENT ZX / SCOUT Starter Motor STARTER MOTOR INSPECTION Connect a battery across the starter motor Starter Motor Battery (+) Terminal and check for its operation. Battery 15-13...

  • Page 177: 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 178: 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 179: Fuel Unit

    . INSTRUMENT/SWITCHES/LIGHTS ZX / SCOUT Fuel Unit FUEL UNIT REMOVAL Remove the frame body cover. ( 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 180: Oil Meter

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

  • Page 181: Switches

    . INSTRUMENT/SWITCHES/LIGHTS ZX / SCOUT Oil Indicator Light 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. ( 12-3) Disconnect the ignition switch wire couplers and check for continuity between the wire terminals.
  • Page 182 . INSTRUMENT/SWITCHES/LIGHTS ZX / SCOUT HEADLIGHT SWITCH INSPECTION Remove the handlebar rear cover. ( 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 ○ ○ ○...

  • Page 183: Stop Switch Inspection/Horn

    . INSTRUMENT/SWITCHES/LIGHTS ZX / SCOUT STARTER SWITCH INSPECTION Check for continuity between wire terminals. 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...

  • Page 184: Bulb Replacement

    . INSTRUMENT/SWITCHES/LIGHTS ZX / SCOUT Horn Battery HORN INSPECTION Remove the frame front cover. ( 12-3) Disconnect the horn wire couplers. horn is normal if it sounds when a 12V battery is connected across the horn wire terminals. FRONT TURN SIGNAL LIGHT REPLACEMENT Remove the turn signal light shell and the bulb.
  • Page 185 . INSTRUMENT/SWITCHES/LIGHTS ZX / SCOUT INSTRUMENT Instrument Bulbs Replacement Remove the handlebar rear cover. ( 12-3) Remove the bulbs and replace with new ones. Bulb Sockets Speedometer cable SPEEDOMETER REMOVAL Disconnect the speedometer cable. Disconnect the speedometer wire connector. Remove the three screws attaching the speedometer.

  • Page 186: 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 187 . 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 188 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM ZX / SCOUT EXHAUST MUFFLER REMOVAL 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 189 . EVAPORATIVE/EXHAUST EMISSION ZX 50 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. EXHAUST EMISSION TEST AND ADJUSTMENT 1.
  • Page 190 NO.: KTI-04002 KYMCO Clean Air System (For EURO 2) The KYMCO Clean Air System is a secondary air suction system that helps the exhaust gases to burn more completely. When the spent fuel charge is released into the exhaust system, it is still hot enough to burn.
  • Page 191 YMCO ECHNICAL NFORMATION Model ALL MODEL (For EURO 2) Date: 8.JAN.04 Subject KYMCO Clean Air System (For EURO 2) NO.: KTI-04002 Secondary Air Suction System Diagram (2-stroke)

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