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KYMCO Scout 50, Service Manual, Page: 2 / 188

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KYMCO Scout 50 Service Manual Download Page 2

1

. SPECIFICATIONS

1-0

ZX / SCOUT 

1 

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 

REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER..............14 

ELECTRICAL EQUIPMENT .................................................................15 

INSTRUMENT/SWITCHES/LIGHTS....................................................16 

EVAPORATIVE/EXHAUST EMISSION CONTRAL SYSTEM...........17 

 
 
 
 
 
 
 

1

Summary of Contents for Scout 50

Page 1: ...tion 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 lubr...

Page 2: ...YLINDER 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 FRO...

Page 3: ...cation type Separate type Oil pump type Plunger type Oil filter type Full flow filtration Lubrication oil capacity liter 0 80 Air cleaner type No Wet single Fuel capacity liter 4 9 Type Plunger type C...

Page 4: ...__________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION ______________...

Page 5: ...2 GENERAL INFORMATION 2 1 ZX SCOUT ENGINE SERIAL NUMBER IDENTIFICATION Location of Engine Serial Number...

Page 6: ...ed greases and lubricants to the specified lubrication points n After reassembly check all parts for proper tightening and operation n When two persons work together pay attention to the mutual workin...

Page 7: ...e connector has a lock lock it at the correct position n Check if there is any loose wire n Before connecting a terminal check for damaged terminal cover or loose negative terminal n Check the double...

Page 8: ...he side of bolts and screws Avoid the projected ends of bolts and screws n Route harnesses so they are neither pulled tight nor have excessive slack n Protect wires and harnesses with electrical tape...

Page 9: ...rate according to the operating instructions n Be careful not to drop any parts n When rust is found on a terminal remove the rust with sand paper or equivalent before connecting n Symbols The followi...

Page 10: ...D 17 005 17 017 17 03 Cylinder bore 39 039 025 39 05 Drive belt width 18 17 Drive pulley collar O D 20 01 20 025 Movable drive face ID 20 035 20 085 19 97 Weight roller O D 13 0 12 4 Clutch outer I D...

Page 11: ...Front rear 4 0 4 0 2 0 2 0 Brake disk runout Front rear 0 30 Rear shock absorber spring free length 235 7 218 7 ELECTRICAL EQUIPMENT SC10AS Capacity 12V3AH Voltage 13 0 13 2V Charging Standard 0 4A 5...

Page 12: ...lt lower mount bolt hex bolt Front damper nut Front pivot arm bolt Rear shock absorber upper mount bolt lower mount bolt lower joint nut 10 25 4 25 4 12 16 8 8 10 8 8 4 5 5 0 8 0 12 0 0 5 1 3 5 0 7 0...

Page 13: ...4 Bearing installation Clutch spring compressor E027 Driven pulley disassembly assembly Crankcase assembly collar E023 Driven shaft crankshaft crankcase assembly Crankcase assembly tool E024 Crankshaf...

Page 14: ...e 6 Starter pinion movable parts Grease FRAME Apply clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and rise the durability of the motorcycle SC10AS...

Page 15: ...2 GENERAL INFORMATION 2 11 ZX SCOUT CABLE HARNESS ROUTING...

Page 16: ...UT Front Brake Reservoir Rear Brake Cable Throttle Cable Ignition Switch Regulator Rectifier Front Brake Fluid Tube Resistor Front Stop Switch Wire Rear Stop Switch Wire Speedometer Cable Speedometer...

Page 17: ...2 GENERAL INFORMATION 2 13 ZX SCOUT Ignition Coil Fuel Unit Wire Harness Rear Brake Cable Throttle Cable Front Brake Fluid Tube Speedometer Cable Speedometer Cable Front Brake Fluid Tube...

Page 18: ...2 GENERAL INFORMATION 2 14 ZX SCOUT Fuel Filter Oil Tank Cap Starter Relay CDI Unit Battery Wire Harness Ignition Coil Oil Tube...

Page 19: ...2 GENERAL INFORMATION 2 15 ZX SCOUT TROUBLESHOOTING Vacuum Tee Oil Pump Ignition Coil Oil Tube Fuel Unit Fuel Tank Cap...

Page 20: ...ely open Faulty auto bystarter ENGINE STOPS IMMEDIATELY AFTER IT STARTS Inspection Adjustment Symptom Probable Cause Check if fuel reaches carburetor by loosening drain screw Remove spark plug and ins...

Page 21: ...if fuel reaches carburetor by loosening drain screw Fuel reaches carburetor Good spark Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Correct timi...

Page 22: ...bystarter ENGINE LACKS POWER Inspection Adjustment Symptom Probable Cause No air leak Not clogged Clogged Air leaks Clogged Not Clogged Connect auto bystarter wire to battery Wait for 5 minutes then c...

Page 23: ...oor quality fuel Clutch slipping Mixture too lean POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Engine speed increases Engine overheats Correct timing Inspection Adjustment Engine does not knock...

Page 24: ...logged Not clogged Inspection Adjustment Symptom Probable Cause Check ignition timing Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Check ignitio...

Page 25: ...n driven face spring Separated clutch lining Clogged Not clogged Engine starts but motor cycle does not move Symptom Probable Cause Connect auto bystarter wire to battery Wait for 5 minutes then conne...

Page 26: ...DOES NOT TRACK STRAIGHT Front and rear tire pressures are normal Steering stem nut too tight Broken steering steel balls Excessive wheel bearing play Bent rim Loose axle nut Misaligned front and rear...

Page 27: ...area Sluggish or elongated brake cables Brake shoes improperly contact brake drum Water and mud in brake system Oil or grease on brake linings Faulty brake master cylinder Faulty brake caliper Oil or...

Page 28: ...rned out fuse Weak or dead battery Faulty ignition switch Inspection Adjustment Symptom Inspection Adjustment Symptom Probable Cause Signals operate properly Signals dim remain on or don t operate Sig...

Page 29: ...does not come on Stoplight comes on Signals operate properly Signals dim remain on or don t operate Pointer does not move Pointer does not move Good Good Pointer moves Pointer moves Pointer moves Poi...

Page 30: ...p turning Faulty starter pinion Starter relay shorted or stuck closed Inspection Adjustment Inspection Adjustment Symptom Symptom Signals operate properly Signals operate properly Signals dim remain o...

Page 31: ...__________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECT...

Page 32: ...play Steering handlebar Operating performance Right left turning angle Suspension Damage Check for front fork pivot installation Check steering stem Front fork Check front fork pivot for looseness and...

Page 33: ...e for damage Rim runout at rim end Front Axial 2 0mm Radial 2 0mm Rear Axial 2 0mm Radial 2 0mm Check front wheel bear ing for excessive play and abnormal noise Check front wheel bear ing for excessiv...

Page 34: ...ator light comes on when oil is insufficient Engine Oil leakage Oil level Lubrica tion system Check oil filter for clogging Fuel leakage Carburetor throttle valve and auto bystarter Check fuel filter...

Page 35: ...within the specified service limit Check the brake operation for abnormal noise and brake drum inside for wear or damage BRAKE DISK LINING Brake Disk Surface and Brake Pad Wear Check the brake disk su...

Page 36: ...t Looseness Check the front and rear axle nuts for looseness If the axle nuts are loose tighten them to the specified torques Torques Front 5 0 7 0kg m Rear 11 0 13 0kg m Wheel Rim Spoke Plate Damage...

Page 37: ...tire shock absorber assembly for looseness or damage POWER DRIVE SYSTEM TRANSMISSION CASE Check the rear wheel transmission case surrounding area for oil leaks Stop the engine and remove the oil check...

Page 38: ...Remove the A C generator fan cover 7 3 Remove the four bolts attaching the fan and then remove the fan Warm up the engine and check the ignition timing with a timing light When the engine is running...

Page 39: ...ge by turning the throttle stop screw and air screw Idle Speed 2100 100rpm Air Cleaner Remove the air cleaner cover by removing the six air cleaner cover screws Remove the air cleaner element The engi...

Page 40: ...is low check for the following Leaking cylinder head gasket Worn piston cylinder If the compression is high it indicates that carbon deposits have accumulated on the combustion chamber and the piston...

Page 41: ...the control cable lock nut and turning the adjusting nut After adjustment tighten the lock nut If the oil pump is not synchronized properly the following will occur Excessive white smoke or hard start...

Page 42: ...rip free play does not fall within the specified range adjust by loosening the lock nut and turning the adjusting nut OTHERS LIGHTS Headlight Adjust the headlight beam by loosening the headlight adjus...

Page 43: ...3 INSPECTION ADJUSTMENT 3 12 Headlight Adjusting Bolt...

Page 44: ..._________________________________ __________________________________________________________________________________ __________________________________________________________________________________...

Page 45: ...4 LUBRICATION SYSTEM 4 1 ZX SCOUT 50 LUBRICATION SYSTEM...

Page 46: ...connecting it SPECIFICATIONS Recommended Motor Oil SAE20W20 2 stroke Motor Oil Oil Capacity 0 80 liter Light comes on 0 25 liter TROUBLESHOOTING Excessive white smoke or carbon deposits on spark plug...

Page 47: ...eakened O ring Damage to crankcase mating surface Damage to pump body Control lever operation Oil leaks through oil seals Worn or damaged pump pinion OIL PUMP INSTALLATION Do not allow foreign matters...

Page 48: ...and oil outlet line properly Connect the oil pump control cable Bleed air from the oil pump OIL PUMP BLEEDING Lubricate the O ring with grease or engine oil before installation Make sure that the oil...

Page 49: ...with oil 2 Start the engine and allow it to idle with the oil control lever in the fully open position Visually check the oil flow 3 If there is no oil flowing out within 1 minute bleed air from the...

Page 50: ...hing the oil tank Disconnect the oil inlet line Drain the oil inside the oil tank into a clean container Remove the oil tank The installation sequence is the reverse of removal Connect the oil line pr...

Page 51: ..._________________________________________________________________________ __________________________________________________________________________________ ___________________________________________...

Page 52: ...ON 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...

Page 53: ...buretor cap Disconnect the oil pump control cable from the pump body Disconnect the oil inlet line from the oil pump Disconnect the auto bystarter A C generator and starter motor wire connectors Remov...

Page 54: ...ower mount bolt Remove the right and left engine mounting nuts Take out the right and left engine mounting bolts Lift the frame upward to separate it from the engine and be careful not to damage the r...

Page 55: ...ine in the reverse order of removal Torque Values Engine mounting bolt 4 5 5 5kg m Rear shock absorber lower mount bolt 2 4 3 0kg m Perform the following inspections and adjustments after installation...

Page 56: ...__________________________________________________________________ __________________________________________________________________________________ __________________________________________________...

Page 57: ...6 CYLINDER HEAD CYLINDER PISTON 6 1 ZX SCOUT Torque 1 5 1 7kg m Torque 1 1 1 7kg m cold...

Page 58: ...der to piston clearance 0 10 Piston pin hole I D 12 002 12 008 12 03 Piston pin O D 11 994 12 0 11 98 Piston to piston pin clearance Piston ring end gap top second 0 10 0 25 0 40 Connecting rod small...

Page 59: ...exhaust muffler lock bolts Remove the bolt attaching the engine hood to remove the engine hood The installation sequence is the reverse of removal Remove the spark plug Remove the cylinder head bolts...

Page 60: ...th a straight edge and feeler gauge Service Limit 0 10mm replace if over CYLINDER HEAD INSTALLATION Install the cylinder head on the cylinder properly Install a new cylinder head gasket onto the cylin...

Page 61: ...or 3 times Torque 1 5 1 7kg m Install the spark plug Torque 1 1 1 7kg m Engine Hood Installation Install the engine hood Install the spark plug cap Perform the following inspections after installation...

Page 62: ...ISTON REMOVAL Remove the piston pin clip to remove the piston pin and piston Spread each piston ring and remove by lifting it up at a point just opposite the gap Remove the expander Do not damage or s...

Page 63: ...d C in both X and Y directions Avoid the port area Take the maximum figure measured to determine the cylinder bore Service Limit 39 05mm replace if over Inspect the top of the cylinder for warpage Ser...

Page 64: ...place if below Measure the piston to cylinder clearance Service Limit 0 10mm replace if over Measure the piston pin hole I D Service Limit 12 03mm replace if over Measure the piston pin O D Service Li...

Page 65: ...ring groove Then install the top and second rings in their respective ring grooves The piston rings should be pressed into the grooves with even force After installation check and make sure that each...

Page 66: ...ngs with engine oil and install the piston into the cylinder while compressing the piston rings Install the cylinder head Torque 1 5 1 7kg m Install the exhaust muffler and tighten the exhaust muffler...

Page 67: ...__________________________________________________________________ __________________________________________________________________________________ __________________________________________________...

Page 68: ...7 A C GENERATOR 7 1 ZX SCOUT Torque 3 5 4 0kg m Torque 0 8 1 2kg m Torque 0 6 1 0kg m Torque 0 8 1 2kg m...

Page 69: ...enerator 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...

Page 70: ...over Remove the cooling fan by removing the four bolts Hold the flywheel with an universal holder and then remove the flywheel nut Remove the A C generator flywheel using the flywheel puller Fan Cover...

Page 71: ...crankcase Remove the two bolts attaching the A C generator stator A C GENERATOR INSTALLATION Install the A C generator stator and pulser coil wire clamp onto the right crankcase and then install the...

Page 72: ...el onto the crankshaft with the flywheel groove aligned with the crankshaft woodruff key Hold the flywheel with the universal holder and install the flywheel flange nut Torque 3 5 4 0kg m Start the en...

Page 73: ..._____________________________________ __________________________________________________________________________________ _______________________________________________________________________________...

Page 74: ...8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY 8 1 ZX SCOUT MODEL SC10AS Torque 3 5 4 5kg m Torque 5 0 6 0kg m...

Page 75: ...06 Drive belt width 18 17 TORQUE VALUES Drive face nut 3 5 4 0kg m Clutch outer nut 3 5 4 5kg m Clutch drive plate nut 5 0 6 0kg m SPECIAL TOOLS Lock nut wrench 39mm Universal holder Clutch spring co...

Page 76: ...K STARTER SPINDLE REMOVAL Remove the kick lever from the kick starter spindle Remove the circlip and washer from the kick starter spindle Slightly rotate the kick starter spindle to remove the kick st...

Page 77: ...ing for weakness or damage Inspect the kick starter spindle bushing for wear or damage Check the kick starter driven gear for wear or damage Check the friction spring for wear or damage Inspect the ki...

Page 78: ...ar and friction spring as the figure shown First install the washer and then the circlip onto the kick starter spindle Install the kick lever If the hooks of the return spring can not be installed pro...

Page 79: ...tighten the nine bolts diagonally Connect the drive belt cooling air tube and install the circlip DRIVE BELT Remove the left crankcase cover INSPECTION Check the drive belt for cracks separation or ab...

Page 80: ...se cover 8 3 Hold the clutch outer with the universal holder and remove the 14mm clutch outer nut and clutch outer Hold the drive pulley with the holder and remove the drive face nut Remove the starti...

Page 81: ...ratchet and washer then tighten the drive face nut Torque 3 5 4 0kg m DRIVE PULLEY REMOVAL Hold the drive pulley with the holder and remove the drive face nut Remove the starting ratchet washer and dr...

Page 82: ...COUT MOVABLE DRIVE FACE DISASSEMBLY Remove the movable drive face and drive pulley collar from the crankshaft Remove the ramp plate Remove the weight rollers Movable Drive Face Ramp Plate Drive Face N...

Page 83: ...replace if below DRIVE PULLEY INSTALLATION Install the drive pulley collar and movable drive face onto the crankshaft Install the drive belt on the crankshaft Install the drive face starting ratchet a...

Page 84: ...pect the starter pinion shaft forcing parts for wear and damage INSTALLATION Apply a small amount of grease to the starter pinion teeth Install the starter pinion in the reverse order of removal CLUTC...

Page 85: ...driven pulley CLUTCH DRIVEN PULLEY DIS ASSEMBLY Compress the clutch driven pulley spring with the clutch spring compressor and remove the 39mm drive plate nut Remove the driven face spring Remove the...

Page 86: ...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 Service Limit 107 5mm replace if b...

Page 87: ...D Service Limit 33 94mm replace if below Check the movable driven face for wear or damage Measure the movable driven face I D Service Limit 34 06mm replace if below Check the guide roller pins for st...

Page 88: ...ace Drive a new outer bearing into the driven face with the sealed end facing up Seat the snap ring in its groove Drive in a new needle bearing into the driven face with the mark facing up Snap Ring B...

Page 89: ...de roller pins O rings and a new oil seal Install the seal collar Set the driven pulley driven face spring and clutch assembly onto the clutch spring compressor Compress the tool and install the 39mm...

Page 90: ...t on the clutch driven pulley and then install the clutch driven pulley onto the drive shaft Install the clutch outer Hold the clutch outer with the universal holder Install and tighten the 10mm clutc...

Page 91: ...________________________________________ __________________________________________________________________________________ ____________________________________________________________________________...

Page 92: ...9 FINAL REDUCTION 9 1 ZX SCOUT...

Page 93: ...se assembly shaft Bearing outer driver 37x40mm Bearing outer driver 32x35mm Bearing driver pilot 17mm Bearing driver pilot 15mm Bearing driver pilot 12mm Bearing outer driver handle A TROUBLESHOOTING...

Page 94: ...clean container Remove the transmission case cover attaching bolts Remove the transmission case cover Remove the gasket and dowel pins Remove the final gear and countershaft FINAL REDUCTION INSPECTION...

Page 95: ...d gear for wear or damage Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage BEARING REPLACEMENT Transmission Do not remove t...

Page 96: ...gs into the transmission case cover BEARING REPLACEMENT Left Crankcase Cover Remove the drive shaft Remove the drive shaft oil seal Remove the left crankcase bearings using the bearing remover Drive n...

Page 97: ...new drive shaft oil seal FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Install the final gear and final shaft into the left crankcase Install the countershaft and gear into...

Page 98: ...et Install the transmission case cover Install and tighten the transmission case cover bolts Install the clutch driven pulley 8 17 Install other removed parts in the reverse order of removal After ins...

Page 99: ...n the oil check bolt Torque 1 0 1 5kg m Start the engine and check for oil leaks Check the oil level from the oil check bolt hole and add the specified oil to the proper level if the oil level is low...

Page 100: ..._____________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE CR...

Page 101: ...10 CRANKCASE CRANKSHAFT 10 1 ZX SCOUT Torque 0 8 1 2kg m...

Page 102: ...assembly When separating the crankcase the bearing will remain in the crankcase and it should be removed When assembling drive a new bearing into the crankcase and install a new oil seal SPECIFICATION...

Page 103: ...se attaching bolts Attach the crankcase puller on the right crankcase and remove the right crankcase from the left crankcase CRANKSHAFT REMOVAL Attach the crankcase puller on the left crankcase and re...

Page 104: ...al 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...

Page 105: ...Check the crankshaft bearings for excessive play The bearings must be replaced if they are noisy or have excessive play CRANKSHAFT INSTALLATION Wash the crankshaft in cleaning solvent and then check f...

Page 106: ...crankshaft into the left crankcase CRANKCASE ASSEMBLY Install the dowel pins and a new gasket to the Bearing Outer Driver Handle A Bearing Outer Driver Handle A Bearing Outer Driver 37x40mm Bearing D...

Page 107: ...semble the crankcase halves The distance between the right crankcase oil seal and crankcase surface is about 12 5 0 5 mm The distance between the left crankcase oil seal and crankcase surface is about...

Page 108: ...10 CRANKCASE CRANKSHAFT 10 8 ZX SCOUT 50 Install and tighten the crankcase attaching bolts Oil Seal 1 0mm...

Page 109: ...______________________________________________ __________________________________________________________________________________ CARBURETOR ___________________________________________________________...

Page 110: ...11 CARBURETOR 11 1 ZX SCOUT...

Page 111: ...speed 2100 100rpm Throttle grip free play 2 6mm SPECIAL TOOL Float level gauge TROUBLESHOOTING Engine does not start Lean mixture No fuel in tank Clogged fuel jets Faulty float valve Too much fuel ge...

Page 112: ...rier 12 5 Remove the met in box 12 4 Loosen the carburetor cap and remove the throttle valve Disconnect the throttle cable from the throttle valve Remove the throttle valve spring carburetor cap and r...

Page 113: ...rottle valve and secure with the needle clip Install the rubber seal on the throttle cable and then install the carburetor cap and throttle valve spring Connect the throttle cable to the throttle valv...

Page 114: ...justment 3 8 Install the met in box CARBURETOR REMOVAL Remove the met in box 12 4 Remove the air cleaner by removing the air cleaner band screw and attaching bolts Disconnect the fuel tube Loosen the...

Page 115: ...o 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 If air cannot be blown into the hose clogged the auto bystart...

Page 116: ...er Remove the two auto bystarter set plate screws to remove the auto bystarter Check the auto bystarter valve and needle for wear or damage Check the O ring for wear or damage AUTO BYSTARTER INSTALLAT...

Page 117: ...nd the float chamber Remove the screw and O ring Remove the float pin float and float valve FLOAT FLOAT VALVE INSPECTION Inspect the float for damage or fuel inside the float Check the float valve sea...

Page 118: ...e them Remove the main jet and needle jet holder CARBURETORPASSAGESCLEANING Blow compressed air through all passages of the carburetor body with an air gun FLOAT CHAMBER ASSEMBLY Install the main jet...

Page 119: ...lve just connecting the float arm Float Level 5 0mm Replace the float if the level is out of the specified level range Install the O ring Check the operation of the float and install the float chamber...

Page 120: ...ns Start the engine and turn the air screw in or out slowly to obtain the highest engine speed Turn the throttle stop screw to obtain the specified idle speed Idle Speed 2100 100rpm Slightly increase...

Page 121: ...valve in the reverse order of removal FUEL TANK 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 f...

Page 122: ...11 CARBURETOR 11 13 ZX SCOUT Fuel Tube Vacuum Tube Auto Fuel Valve...

Page 123: ...__________________________________________________________________________________ __________________________________________________________________________________ __________________________________...

Page 124: ...12 FRAME COVERS 12 1 ZX SCOUT ASSEMBLY DRAWING...

Page 125: ...ont cover Handlebar rear cover Front cover Headlight wire Handlebar rear cover Speedometer cable and instrument light wire connectors etc Frame body cover Met in box rear carrier Floor board Rear carr...

Page 126: ...ER COVERS REMOVAL First remove the front cover Remove the right and left side rails by removing the two screws for each rail Remove the two bolts and three screws attaching each of the front right and...

Page 127: ...move the bottom cover The installation sequence is the reverse of removal MET IN BOX REMOVAL Open the seat Remove the two bolts two nuts and the center bolt attaching the met in box Remove the oil tan...

Page 128: ...OVERS 12 5 FRONT FENDER REMOVAL Remove two bolts attaching each side of the front fender Remove the front fender The installation sequence is the reverse of removal Rear Carrier Bolts Screws Front Fen...

Page 129: ...___________________________ __________________________________________________________________________________ __________________________________________________________________________________ STEERI...

Page 130: ...13 STEERINGHANDLEBAR FRONTWHEEL FRONT BRAKE FRONTSHOCKABSORBER FRONTFORK 13 1 ZX SCOUT SERVICE INFORMATION 4 5kg m 2 7kg m 6 0kg m 3 3kg m...

Page 131: ...mm Pilot 10mm Rear shock absorber remover Bearing puller Rear shock absorber compressor Snap ring pliers close Ball race remover Damper compressor TROUBLESHOOTING Hard steering heavy Contaminated brak...

Page 132: ...ver holder Remove two bolts attaching the brake master cylinder disk brake to the right brake lever Remove the two right handlebar switch housing bolts and separate the housing Disconnect the throttle...

Page 133: ...stem Install and tighten the handlebar lock nut Torque 4 5 5 0kg m Lubricate the throttle pipe front end with grease Install the throttle grip and connect the throttle cable The installation sequence...

Page 134: ...set screw and disconnect the speedometer cable Remove the front axle nut and pull out the axle Remove the front wheel Remove the brake panel side collar INSPECTION Set the axle in V blocks and measur...

Page 135: ...FORK 13 6 ZX SCOUT 50 Radial 2 0mm replace if over Axial 2 0mm replace if over Turn the wheel bearings and replace them if they have excessive play or noise DISASSEMBLY Remove the dust seal Remove the...

Page 136: ...g cavities with grease Drive in the left bearing Install the distance collar Drive in the right bearing Apply grease to the dust seal lip and install the dust seal Install the side collar Bearing Pull...

Page 137: ...NTFORK 13 8 ZX SCOUT 50 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 HYDRAULIC BRAKE FRONT BRAKE Bra...

Page 138: ...rake pads must be replaced as a set to ensure the balance of the brake disk When operating the brake lever the brake reservoir cap must be tightened securely to avoid spill of brake fluid When servici...

Page 139: ...asure the brake disk thickness Service Limit 3 0mm Measure the brake disk runout Service Limit 0 3mm BRAKE MASTER CYLINDER Removal First drain the brake fluid from the hydraulic brake system When serv...

Page 140: ...ster cylinder 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 Inspection Measure the brake master c...

Page 141: ...all the main piston spring and snap ring Install the rubber cover Install the brake lever Place the brake master cylinder on the handlebar and install the holder with up mark facing up Be sure to alig...

Page 142: ...reservoir with recommended brake fluid to the upper limit and bleed air according to the method stated in 13 9 BRAKE CALIPER FRONT Removal Remove the brake caliper 13 10 Place a clean container under...

Page 143: ...a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratch or wear and replace if necessary Push the piston oil seal outward to remove it...

Page 144: ...oil seal Lubricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved side facing out Wipe off excessive brake fluid with a clean shop towel Apply s...

Page 145: ...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 13 9 FRONT SHOCK ABSORBER REMOVAL Remove the front...

Page 146: ...the front shock absorber and remove the shock absorber tube hex bolt and copper washer from the front shock absorber Use a vise to hold the front shock absorber tube and remove the damper from the sho...

Page 147: ...OCKABSORBER ASSEMBLY Install the damping spring to the damper and then install them into the front shock absorber tube Install the front shock absorber spring and tighten the damper nut Install the fr...

Page 148: ...cket hex bolt and install them together Torque 1 5 3 0kg m Specified Oil ss 8 Oil Capacity 61cc Install the circlip Install the dust boot INSTALLATION Install the front shock absorbers onto the steeri...

Page 149: ...ne race and remove the steering stem lock nut Remove the top cone race and remove the front fork Inspect the ball races cone races and steel balls for wear or damage Replace if necessary BOTTOMCONERAC...

Page 150: ...ll races INSTALLATION Apply grease to top and bottom ball races and install 26 steel balls on the top ball race and 29 steel balls on the bottom ball race Apply grease to the ball races again and then...

Page 151: ...ng stem right and left several times to make steel balls contact each other closely Install the steering stem lock nut and tighten it while holding the top cone race Torque 8 0 12 0kg m Install the fr...

Page 152: ...________________________________________________________ __________________________________________________________________________________ ____________________________________________________________...

Page 153: ...14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER 14 1 ZX SCOUT 11 0kg m 4 5kg m 3 0kg m...

Page 154: ...Rear shock absorber lower mount bolt 2 4 3 0kg m Rear shock absorber lower joint nut 3 5 4 5kg m apply locking agent SPECIAL TOOL Rear shock absorber remover Rear shock absorber compressor TROUBLESHOO...

Page 155: ...the rear axle nut to remove the rear wheel INSPECTION Measure the rear wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over INSTALLATION Install the rear wheel and...

Page 156: ...Measure the brake lining thickness Service Limit 2 0mm replace if below REAR BRAKE DISASSEMBLY Remove the rear brake adjusting nut and disconnect the rear brake cable Remove the rear brake shoes Remo...

Page 157: ...arm onto the brake cam Install and tighten the brake arm bolt Install the brake arm return spring Install the brake shoes Install the brake arm pin Connect the brake cable and install the adjusting n...

Page 158: ...14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER 14 6 ZX SCOUT Adjust the rear brake lever free play 3 4 REAR SHOCK ABSORBER REMOVAL Remove the rear carrier 12 5 Brake Arm Adjusting Nut Brake Arm Pin...

Page 159: ...mpressor as the figure shown Compress the rear shock absorber spring Loosen the lower joint lock nut Remove the lower joint Remove the lock nut rubber and damper INSPECTION Inspect the damper rod for...

Page 160: ...the rear shock absorber in the reverse order of disassembly Tighten the lock nut Torque 3 5 4 5kg m INSTALLATION Install the rear shock absorber Install the rear shock absorber upper mount bolt and th...

Page 161: ...14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER 14 9 ZX SCOUT Torque Upper Mount Bolt 3 5 4 5kg m Lower Mount Bolt 2 4 3 0kg m Install the frame body cover 12 5 Upper Mount Bolt Lower Mount Bolt...

Page 162: ...________________________________________________ __________________________________________________________________________________ ____________________________________________________________________...

Page 163: ...ndard 0 4A 10H Battery current Quick 4A 0 5H Spark plug NGK BR8HSA Spark plug gap 0 6 0 7mm Primary coil 0 153 0 187 Secondary coil with plug cap 6 99 10 21K Ignition coil resistance Secondary coil wi...

Page 164: ...lug Faulty ignition switch Poorly insulated plug cap Faulty ignition coil Improper ignition timing Faulty CDI unit Battery voltage too low 6V max Faulty A C generator Faulty CDI unit STARTING SYSTEM S...

Page 165: ...15 ELECTRICAL EQUIPMENT 15 3 ZX SCOUT CHARGING SYSTEM A C Generator Dimmer Switch Headlight Switch Ignition Switch Regulator Rectifier Resistor Battery 7A P G B...

Page 166: ...ver and disconnect the battery cables Measure the voltage between the battery terminals Fully charged 13 0V 13 2V Undercharged 12 3V max CHARGING METHOD Connect the charger positive cable to the batte...

Page 167: ...ion RPM Day Night 2500 1 3A min 1 0A min 6000 2 0A min 2 0A min ChargingLimitVoltage 14 5 0 5V 8000rpm If the limit voltage is not within the specified range check the regulator rectifier A C GENERATO...

Page 168: ...the front cover 12 3 Disconnect the regulator rectifier wire coupler and remove the bolt to remove the regulator rectifier Measure the resistances between the terminals Replace the regulator rectifier...

Page 169: ...15 ELECTRICAL EQUIPMENT 15 7 ZX SCOUT IGNITION SYSTEM IGNITION COIL INSPECTION Continuity Test Ignition Coil Pulser Coil Ignition Switch CDI Unit A C Generator Exciter Coil Pulser Coil...

Page 170: ...sure the secondary coil resistance between the spark plug cap and the primary coil terminal as Figure A shown Resistance 20 with plug cap 6 99 10 21K Measure the secondary coil resistance between the...

Page 171: ...n 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 80 160 CDI UNIT INSPECTION Remove the...

Page 172: ...not within the specifications in the table below Use the x K range for the Sanwa Tester Use the x 100 range for the Kowa Tester Unit K Probe Probe Black Yellow Black Red Black White Blue Yellow Green...

Page 173: ...X SCOUT Starting System STARTER RELAY INSPECTION Remove the battery cover Disconnect the starter relay coupler and then Starter Button Ignition Switch Starter Relay Battery Starter Button Starter Butt...

Page 174: ...tarter relay red and red white terminals The relay is normal if there is continuity STARTER MOTOR REMOVAL Disconnect the starter motor cable Remove the two bolts attaching the starter motor and remove...

Page 175: ...15 ELECTRICAL EQUIPMENT 15 13 ZX SCOUT Battery...

Page 176: ...________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSTRUMEN...

Page 177: ...icient Burned bulb Fuse burned out Faulty switch Dead battery Broken or shorted wire Faulty ignition switch Fuse burned out Faulty instrument Weak battery Faulty oil meter Poorly connected wire Faulty...

Page 178: ...Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions Wire Terminals Upper Lower G Y W 33 686 G L W 566 53 Y W L W 600 600 FUEL GAUGE INSPECTION Conne...

Page 179: ...the oil meter float at the lower position Measure the resistances between the wire terminals as and shown in the left figure Wire Terminals Resistance Green Red Black 5 16 Green Black Oil Meter Opera...

Page 180: ...witch wire couplers and check for continuity between the wire terminals Color Red Black White Green Black Symbol BAT1 IG E BAT2 LOCK OFF ON IGNITION SWITCH REPLACEMENT Remove the front cover 12 3 Disc...

Page 181: ...L TL RE OFF P H DIMMER SWITCH INSPECTION Check for continuity between wire terminals Color Blue White Blue White Black Symbol HL HI LO PASS HI LO PASSING TURN SIGNAL SWITCH INSPECTION Check for contin...

Page 182: ...Color Light Green Black Symbol HO BAT2 FREE PUSH STOP SWITCH INSPECTION Remove the handlebar front cover 12 3 Disconnect the front and rear stop switch wire couplers Check for continuity between the...

Page 183: ...SIGNAL LIGHT BULB REPLACEMENT Taillight Shell Removal Remove two screws attaching the taillight shell Remove the taillight shell and stop light bulb Remove the rear turn signal light bulbs The instal...

Page 184: ...ter The installation sequence is the reverse of removal HEADLIGHT REMOVAL BULB REPLACEMENT Remove the handlebar front cover 12 3 Remove the bulb sockets and bulbs The installation sequence is the reve...

Page 185: ..._______________________________________________________ __________________________________________________________________________________ _____________________________________________________________...

Page 186: ...in the exhaust emission The precious metal in the oxidizing catalytic converter is used to oxidize HC and CO in the exhaust emission into CO2 and H2O to avoid air pollution TROUBLESHOOTING Engine run...

Page 187: ...temperature of exhaust muffler is very high Be careful to avoid burns during working Exhaust Muffler Lock Bolts Exhaust Muffler Joint Lock Nut A large amount of unburned mixture flowing into the high...

Page 188: ...ADJUSTMENT 1 Start the engine and warm up for several minutes Engine surface temperature 50 60 2 Adjust the idle speed to 2000 100rpm 3 Connect the emission tester sampling pipe to the exhaust muffle...

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