KYMCO ZX/SCOUT 50 Service Manual Download Page 2

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. SPECIFICATIONS

1-0

ZX / SCOUT

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

Summary of Contents for ZX/SCOUT 50

Page 1: ...ion 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 assemb...

Page 2: ...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 ...

Page 3: ...ication 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 Carburetor Piston dia mm Venturi dia mm 14 Ignition system type CDI electromagnetic Ignition Ignition timing F mark 15 5 2 BTDC 2000rpm Spark NGK BR8HSA plug ND Spark plug gap mm 0 6 0 7 Battery capac...

Page 4: ...__ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ ENGINE SERIAL NUMBER IDENTIFICATION 2 1 SERVICE PRECAUTIONS 2 2 SERVICE INFORMATION 2 6 TORQUE VALUES 2 8 SPECIAL TOOLS 2 9 LUBR...

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

Page 6: ...engine oil before reassembly Apply or add designated greases and lubricants to the specified lubrication points After reassembly check all parts for proper tightening and operation When two persons work together pay attention to the mutual working safety Disconnect the battery negative terminal before operation When using a spanner or other tools make sure not to damage the motorcycle surface Afte...

Page 7: ... protruding or loose The connector shall be inserted completely If the double connector has a lock lock it at the correct position Check if there is any loose wire Easy confirm Before connecting a terminal check for damaged terminal cover or loose negative terminal Check the double connector cover for proper coverage and installation Insert the terminal completely Check the terminal cover for prop...

Page 8: ...ted ends of bolts and screws Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws Route harnesses so they are neither pulled tight nor have excessive slack Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner When rubber protecting cover is used to protect the wire harnesses it shall be installed s...

Page 9: ...operating methods thoroughly and operate according to the operating instructions Be careful not to drop any parts When rust is found on a terminal remove the rust with sand paper or equivalent before connecting Symbols The following symbols represent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use designated engine oil for lubrication...

Page 10: ... D 17 005 17 017 17 03 Cylinder bore 39 0 39 025 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 107 107 2 107 5 Driven face spring free length 87 9 82 6 Driven face O D Movable driven face I D Connecting rod big end side clearance Connecting rod big end radial clearance Crankshaft runout A B C...

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 5H Battery current Quick 4A 0 5H Spark plug NGK BR8HSA Spark plug gap 0 6 0 7mm Primary coil 0 153 0 187Ω Secondary coil with plug cap 6 99 10 21KΩ Ignition coil resistance Secondary coil without plug c...

Page 12: ...olt 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 11 0 13 0 3 3 3 3 1 5 3 0 1 5 3 0 3 5 4 5 2 4 3 0 1 5 2 5 Flange bolt U nut Flange U nut Flange U nut Flange nut Flange bolt U nut Cross head Apply locking agent Flange screw U nut Flange nut Torque ...

Page 13: ...28x30mm E014 Bearing installation Clutch spring compressor E027 Driven pulley disassembly assembly Crankcase assembly collar E023 Driven shaft crankshaft crankcase assembly Crankcase assembly tool E024 Crankshaft crankcase assembly Ball race remover F005 Steering stem bearing races Rear shock absorber compressor F004 Rear shock absorber disassembly assembly Universal holder E017 Flywheel holding F...

Page 14: ...movable parts Grease 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 Rear Brake Cable Front Rear Brake Lever Seat Lock Rear Wheel Bearing Throttle Cable Main Stand Pivot Grease Engine Oil Grease Engine Oil Speedometer Gear Brake Cam Front Shock Absorber Lo...

Page 15: ...2 GENERAL INFORMATION 2 11 ZX SCOUT SC10AS WIRING DIAGRAM ...

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

Page 17: ...2 GENERAL INFORMATION 2 13 ZX SCOUT 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 Unit Ignition Coil 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 Fuel Unit Fuel Tank Cap Vacuum Tee Oil Pump Ignition Coil Oil Tube ...

Page 20: ...t ignition timing cFlooded carburetor dThrottle valve excessively open cFaulty auto bystarter Check if fuel reaches carburetor by loosening drain screw Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Inspection Adjustment Fuel reaches carburetor Spark jumps Dry spark plug Not clogged Normal compression Engine does not fire Fuel does not reach ca...

Page 21: ...rn screw out dMixture too lean turn screw in Check if fuel reaches carburetor by loosening drain screw Inspection Adjustment Symptom 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 timing Correctly adjusted Plug not fouled or discolored Normal compression Not Clogged Fuel does not reach carburetor Weak ...

Page 22: ...starter cFaulty auto bystarter Inspection Adjustment Symptom No air leak Not clogged Clogged Air leaks Clogged Not Clogged Remove auto bystarter connecting wire and check if bypass fuel line is clogged Connect auto bystarter wire to battery Wait for 5 minutes then connect a hose to fuel enriching circuit and then blow the hose with mouth Check carburetor gasket for air leaks Probable Cause ...

Page 23: ...ombustion chamber dPoor quality fuel eClutch slipping fMixture too lean Inspection Adjustment Symptom Engine speed increases Engine overheats Correct timing Engine does not knock Plug not fouled or discolored Normal compression Not Clogged Engine speed does not increase ffi i tl Engine does not overheats Incorrect timing Engine knocks Plug fouled or discolored Abnormal compression Clogged Start en...

Page 24: ...wire dFaulty auto bystarter Inspection Adjustment Symptom Clogged Not clogged Incorrect timing Correct timing Check carburetor air screw adjustment Check ignition timing Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Correctly adjusted Incorrectly adjusted No air leak Air leaks Good spark Weak or inter mittent spark Not clogged Clogged Check ca...

Page 25: ...er Inspection Adjustment Symptom Clogged Not clogged Correct timing Incorrect timing Fuel flows freely Fuel flow restricted Not clogged Clogged Not clogged Clogged Check auto fuel valve for fuel supply Check carburetor jets for clogging Remove auto bystarter connecting wire and check if bypass fuel line is clogged Connect auto bystarter wire to battery Wait for 5 minutes then connect a hose to fue...

Page 26: ...uled drive belt dWorn drive belt eWeak driven face spring fWorn or seized driven pulley bearings STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Front and rear tire pressures are normal cSteering stem nut too tight dBroken steering steel balls cExcessive wheel bearing play dBent rim eLoose axle nut cMisaligned front and rear wheels dBent front fork Engine starts but motor cycle does not Engine lacks po...

Page 27: ...e cam fWorn brake drum cWorn brake linings dForeign matter on brake linings eRough brake drum contacting area cSluggish or elongated brake cables dBrake shoes improperly contact brake drum eWater and mud in brake system fOil or grease on brake linings cFaulty brake master cylinder dFaulty brake caliper eOil or grease on brake disk fDeformed brake disk gLeaking brake fluid tube Suspension is too so...

Page 28: ...d connector dBroken wire harness eIncorrectly connected wire cFaulty float dBroken or shorted wire in meter cDamaged oil tank dForeign matters in oil tank Inspection Adjustment Symptom Check battery circuit by operating turn signals Bulb lights Bulb does not light Check connectors for proper operation Good Faulty Remove oil meter and check operation of indicator light by moving float Check connect...

Page 29: ...ire in fuel gauge Inspection Adjustment Symptom Check battery circuit by operating turn signals Signals operate properly Signals operate properly Signals dim remain on or don t operate Signals dim remain on or don t operate Pointer does not move Remove fuel unit and check operation of pointer by moving float up and down Pointer does not move Good Good Pointer moves Pointer moves Pointer moves Poin...

Page 30: ...stuck Inspection Adjustment Inspection Adjustment Inspection Adjustment Symptom Symptom Symptom Probable Cause Stoplight does not come on Signals operate properly Check battery circuit by operating turn signals Stoplight comes on Check operation of stop switch by applying brake Signals operate properly Signals dim remain on or don t operate Signals dim remain on or don t operate Starter motor turn...

Page 31: ..._____________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION ADJUSTMENT __________________________________________________________________________________ INSPECTION AND MAINTENANCE SCHEDULE 3 1 BRAKE SYSTEM 3 4 MOVING DEVICE 3 5 DAMPING DEVICE 3 6 POWER...

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 abnormal noise Check steering stem Front rear brake lever free play Free play 10 20mm Brake lever operation Brake Lever Brake performance Lever Cable Looseness abnormal noise and damage Brake System...

Page 33: ...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 excessive play and abnormal noise Frame Spring Damage Shock spring free length Suspen si on arm Connecting parts loose ness and arm damage Shock Oil leakage and damage Damping Device absorber Assembly parts loose ness abnormal noise...

Page 34: ...brica tion system Check oil filter for clogging Fuel leakage Carburetor throttle valve and auto bystarter Check fuel filter for clogging Fuel level Fuel System Fuel tube replacement Every 4 years Operation Lights Winker Winking action dirt and damage Buzzer Steering Lock Operation Rearview Mirror Reflector Rearview mirror position Rearview Mirror Reflector License Plate Dirt and damage Counter Ope...

Page 35: ... 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 surface for scratch Check if the brake pad wear is within the specified service limit Brake Disk Runout Inspection Jack the motorcycle wheels off the ground and check if the brake disk runout is within the specified service limit BRAKE FLUID LEVEL INSPECTION Bra...

Page 36: ...Nut Axle Shaft 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 Check the wheel rim and spoke plate for wear or damage and measure the rim runout Brake Master Cylinder Tire pressure should be checked when tires are cold Axle Nut Rear Wheel ...

Page 37: ...heck the entire 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 bolt The gear oil level shall be at the oil check bolt hole If the oil level is low add the specified oil to the proper level Specified Gear Oil SAE10W90 Install and tighten the oil check ...

Page 38: ...the fouling and carbon deposits with a spark plug cleaner or wire brush Specified Spark Plug BR8HSA Spark Plug Gap 0 6 0 7mm Ignition Apparatus Remove the right side rail Ö12 4 Remove the A C generator fan cover Ö7 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 15 5 2 BTDC 2000rpm Gap Wear and Fouling Deposits ...

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 F Mark Throttle Stop Screw The engine must be warm for accurate idle speed adjustment Air Screw Screws Air Cleaner ...

Page 40: ...er Compression Remove the spark plug and insert a compression gauge Open the throttle valve fully and push the starter button for 7 8 seconds to test the compression Compression 11 5kg cm If the compression 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 ...

Page 41: ...ing 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 starting due to pump control lever excessively open Seized piston due to pump control lever insufficiently open Filter Screen Oil Filter Connect the oil tubes securely Install the tube clip at the oil ...

Page 42: ...olt 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 If the throttle grip free play does not fall within the specified range adjust by loosening the lock nut and turning the adjusting nut OTHERS LIGHTS Lock Nut Adjusting Nut ...

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

Page 44: ...__________________________________ 4 __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION 4 2 TROUBLESHOOTING 4 2 OIL PUMP REMOVAL 4 3 OIL PUMP INSPECTION 4 3 OIL PU...

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

Page 46: ...e 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 Oil pump not properly synchronized excessive oil Poor quality oil Engine overheating Oil pump not properly adjusted insufficient oiling Poor quality oil Seized piston No oil in tank or clogged oil l...

Page 47: ...owing items Weakened O ring Damage to crankcase mating surface Damage to pump body Control lever operation Oil leaks through oil seals Worn or damaged pump pinion Control Cable Oil Pump Oil Outlet Line Do not allow foreign matters to enter the crankcase Before removing the oil pump clean the oil pump and crankcase surfaces Oil Inlet Line Control Cable plate Before disconnecting the oil line clip t...

Page 48: ...ct the oil inlet line and oil outlet line properly Connect the oil pump control cable Bleed air from the oil pump 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 Oil Outlet Line Control Cable ...

Page 49: ...of the tube by filling it 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 oil inlet line and oil pump Oil Outlet Line 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 ...

Page 50: ...two bolts attaching 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 Wire Connector Connect the oil line properly Bleed air from the oil pump after installation The oil tube clip at the oil tank side must be locked from inside of the oil tube joint ...

Page 51: ...__________________________________________________________________________ __________________________________________________________________________________ 5 __________________________________________________________________________________ ENGINE REMOVAL INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION 5 1 ENGINE REMOVAL 5 2 ENG...

Page 52: ...ION 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 3 5 4 5kg m 4 5 5 5kg m 4 5 5 5kg m ...

Page 53: ...arburetor 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 Remove the spark plug cap Air Cleaner Case Band Carburetor Cap Bolt AC Generator Wire Connector Oil Inlet Line After the oil inlet line is disconnected plug the oil line opening to prevent oil from flowi...

Page 54: ... shock absorber lower 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 rear fender ENGINEHANGERBRACKET REMOVAL Remove the engine hanger bracket bolt and engine hanger bracket The installation sequence is the reserve of removal Torque 3 5 4 5kg m Rear Shoc...

Page 55: ... Install the engine 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 Throttle cable Oil pump control cable Ö3 10 Rear brake cable Ö3 4 Oil pump bleeding Ö4 5 Engine Hanger Bushings Stopper Rubbers Cables and wires should be routed properly ...

Page 56: ...5 ENGINE REMOVAL INSTALLATION 5 5 ZX SCOUT ...

Page 57: ...___________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 6 CYLINDER HEAD CYLINDER PISTON __________________________________________________________________________________ SERVICE INFORMATION 6 2 TROUBLESHOOTING 6 2 CYLINDE...

Page 58: ...6 CYLINDER HEAD CYLINDER PISTON 6 1 ZX SCOUT Torque 1 1 1 7kg m cold Torque 1 5 1 7kg m ...

Page 59: ...r 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 end I D 17 005 17 017 17 03 Cylinder bore 39 0 39 025 39 05 TORQUE VALUES Cylinder head bolt 1 5 1 7kg m Exhaust muffler joint lock nut 1 0 1 4kg m Exhaust muffler lock bolt 3 0 3 6kg m Spark plug 1 1 1...

Page 60: ...ve the two 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 and the cylinder head Remove the cylinder head gasket Spark Plug Cap Loosen the bolts diagonally in 2 or 3 times Cylinder head Bolts Bolts Fan Cover Engine Hood When installing the exhaust ...

Page 61: ...for warpage with 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 cylinder Combustion Chamber Avoid damaging the combustion cham ber wall and cylinder mating f Mating Surface Cylinder head Gasket Be careful not to damage the mating surfaces ...

Page 62: ... 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 Compression test Abnormal engine noise Cylinder air leaks Cylinder head Bolts Spark Plug Cylinder Head Spark Plug Engine Hood Bolt Bolts ...

Page 63: ...gasket PISTON 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 Joint Lock Nuts Cylinder Do not pry between the cylinder and crankcase or strike the fins Piston Piston Pin Do not damage or scratch the piston Do not apply side force to the connect ing rod when removing the p...

Page 64: ... exhaust port area Measure the cylinder bore at three levels of A B and 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 Service Limit 0 10mm replace if over Be careful not to damage the cylinder inside wall ...

Page 65: ...ervice 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 Limit 11 98mm replace if below Measure the piston to piston pin clearance Service Limit 0 03mm replace if over 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 A Mark Nut...

Page 66: ...R INSTALLATION First install the expander in the second 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 ring is flush with the piston at several points around the ring A ring that will not compress means that the ring groove has carbon deposits in ...

Page 67: ... Lubricate the cylinder inside and piston rings 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 joint lock nuts Torque 1 0 1 4kg m Tighten the exhaust muffler lock bolts Torque 3 0 3 6kg m Install the frame covers Cylinder Gasket Ring Pins Be careful ...

Page 68: ...___________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 7 A C GENERATOR __________________________________________________________________________________ SERVICE INFORMATION 7 2 A C GENERATOR REMOVAL 7 3 A C GENERATOR INS...

Page 69: ...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 70: ...MATION 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: ... Remove the three bolts attaching the fan cover to remove the fan cover Remove the cooling fan by removing the four bolts Hold the flywheel with an universal holder and then remove the flywheel nut Bolts Fan Cover Bolt Nut Universal Holder Cooling Fan ...

Page 72: ...ase Remove the pulser coil wire clamp from the right crankcase Remove the two bolts attaching the A C generator stator A C GENERATORINSTALLATION Install the A C generator stator and pulser coil wire clamp onto the right crankcase and then install the pulser coil Lock Nut Wrench Flywheel Puller A C Generator Wire Connector Stator Wire Clamp Be careful not to damage the discon nected wire Pulser Coi...

Page 73: ...ay Install the flywheel 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 engine and check the ignition timing Ö3 7 Install other removed parts in the reserve order of removal A C Generator Wire Connector Woodruff Key Universal Holder ...

Page 74: ...______________________________________ __________________________________________________________________________________ __________________________________________________________________________________ KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY __________________________________________________________________________________ 8 SERVICE INFORMATION 8 2 TROUBLESHOOTING 8 2 KICK STARTER 8 3 DR...

Page 75: ...8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY 8 1 ZX SCOUT MODEL SC10AS Torque 5 0 6 0kg m Torque 3 5 4 5kg m ...

Page 76: ...ace I D 34 0 34 25 34 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 compressor Lock nut socket wrench 32mm Bearing outer driver 37x40mm Bearing driver pilot 17mm One way clutch puller Outer driver 24x26mm TROUBLESHOOTING Poor performance at high spe...

Page 77: ... pins Inspect the left crankcase cover seal rubber for damage or deterioration KICK 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 starter driven gear together with the friction spring Bolt Left Crankcase Cover Kick Starter Spindle Circlip Washer Fric...

Page 78: ... SPINDLE INSPECTION Inspect the kick starter spindle and gear for wear or damage Inspect the return spring for weakness or damage Inspect the kick starter spindle bushing for wear or damage Check the kick starter driven gear for wear or damage Check the friction spring for wear or damage Kick Starter Spindle Return Spring Spindle Spindle Bushing washer Friction Spring Kick Starter Driven Gear ...

Page 79: ...and return spring onto the left crankcase cover Properly install the kick starter driven gear and friction spring as the figure shown Kick Starter Spindle Forcing Part Kick Starter Driven Gear Forcing Part If the hooks of the return spring can not be installed properly use a screw driver to press them into their locations respectively Return Spring Kick Starter Spindle Friction Spring Kick Starter...

Page 80: ...ASE COVER INSTALLATION First install the dowel pins and then the seal rubber Install the left crankcase cover and tighten the nine bolts diagonally Connect the drive belt cooling air tube and install the circlip Washer Circlip Dowel Pins Left Crankcase Cover For drum brake note the location of the brake cable clamp and install the rear brake cable in place with the clamp ...

Page 81: ...m replace if below REPLACEMENT Remove the nine left crankcase cover bolts and left crankcase cover Ö8 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 starting ratchet Remove the drive pulley face Use specified genuine parts for replace ment Clutch Outer Nut Clutch ...

Page 82: ...tall a new drive belt Set the drive belt on the drive pulley Install the drive pulley face starting ratchet and washer then tighten the drive face nut Torque 3 5 4 0kg m Clutch Driven Pulley Drive Belt Drive Belt Drive Pulley Face Drive Belt Drive Face Nut When installing the drive face nut make sure that the tooth spaces of the drive pulley face and starting ratchet align with the teeth of the cr...

Page 83: ...lder and remove the drive face nut Remove the starting ratchet washer and drive pulley face MOVABLE DRIVE FACE DISASSEMBLY Remove the movable drive face and drive pulley collar from the crankshaft Remove the ramp plate Drive Pulley Face Starting Ratchet Drive Face Nut Movable Drive Face Drive Pulley Collar Ramp Plate ...

Page 84: ... MOVABLE DRIVE FACE INSPECTION Check each weight roller for wear or damage Measure each roller O D Service Limit 12 4mm replace if below DRIVE PULLEY INSTALLATION Install the drive pulley collar and movable drive face onto the crankshaft Weight Roller Movable Drive Face Drive Pulley Collar ...

Page 85: ...ley Ö8 9 Remove the starter pinion INSPECTION Inspect the starter pinion seat for wear Inspect the starter pinion for smooth operation Inspect 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 Drive Pulley Face Keep grease or oil off the drive belt and drive p...

Page 86: ...tch outer nut Remove the clutch outer Remove the clutch driven pulley Remove the drive belt from the clutch 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 Clutch Outer 14mm Clutch Outer Nut Universal Holder Clutch Driven Pulley Lock Nut Wrench 39mm Clutch Sp...

Page 87: ... 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 Service Limit 107 5mm replace if below ...

Page 88: ... below Measure the driven face spring free length Service Limit 82 6mm replace if below Check the driven face assembly for wear or damage Measure the driven face O D Service Limit 33 94mm replace if below Check the movable driven face for wear or damage Measure the movable driven face I D Service Limit 34 06mm replace if below Check the guide roller pins for stepped wear ...

Page 89: ...e or abnormal noise Drive the inner bearing out of the driven pulley face Remove the snap ring and drive the outer bearing out of the driven face Drive a new outer bearing into the driven face with the sealed end facing up Seat the snap ring in its groove Snap Ring Bearing Outer Driver 37x40mm Outer Bearing Pack all bearing cavities with 5 0 5 6g grease Specified grease 230 Heat resistant grease ...

Page 90: ...e driven face with the mark facing up CLUTCH DRIVEN PULLEY ASSEMBLY First install the movable driven face onto the driven face Then install the guide roller pins O rings and a new oil seal Install the seal collar Bearing Driver Pilot Outer Driver 24x26mm Oil Seal Driven Pulley O rings Guide Roller Pin ...

Page 91: ...39mm nut to the specified torque Torque 5 0 6 0kg m CLUTCH DRIVEN PULLEY INSTALLATION Install the drive belt 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 clutch outer nut Torque 3 5 4 5kg m Install the left crankcase cover Ö8 6 Clutch Driven Pulley Clu...

Page 92: ..._________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SERVICE INFORMATION 9 2 9 TROUBLESHOOTING 9 2 FINAL REDUCTION DISASSEMBLY 9 3 FINAL REDUCTION...

Page 93: ...9 FINAL REDUCTION 9 1 ZX SCOUT ...

Page 94: ...r Crankcase 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 Engine starts but motorcycle won t move Damaged transmission Seized or burnt transmission Abnormal noise Worn seized or chipped gears Worn bearing Oil leaks Oil level too high Worn or damaged...

Page 95: ...rain the transmission gear oil into a 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 Inspect the countershaft and gear for wear or damage Driver Driver shift Final Gear Countershaft Dowel Pin Countershaft Bolts ...

Page 96: ...r wear or damage Inspect the drive shaft and 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 Final Shaft Drive Shaft Bearing Oil Seal Do not remove the transmission case cover except for necessary part replace ment When replacing the drive shaft also replace the bearing and il l ...

Page 97: ...e final shaft oil seal Drive new bearings 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 Shaft Bearing Bearing Remover Set Bearing Outer Driver Handle A Bearing Outer Driver 32x35mm Bearing Remover Set 12mm ...

Page 98: ... new bearings into the left crankcase Install a 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 Bearing Outer Driver Drive Shaft ...

Page 99: ...nto the counter shaft Install the dowel pins and a new gasket Install the transmission case cover Install and tighten the transmission case cover bolts Install the clutch driven pulley Ö8 17 Install other removed parts in the reverse order of removal Dowel Pins Countershaft Resin Washer Transmission Case Cover Bolts ...

Page 100: ...change 0 1 liter Install and tighten 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 Place the motorcycle on its main stand on level ground Check the sealing washer for wear or damage Drain Bolt Oil Check Bolt Hole Filler ...

Page 101: ..._____________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE CRANKSHAFT __________________________________________________________________________________ SERVICE INFORMATION 10 2 TROUBLESHOOTING 10 2 CRANKCASE SEPARATION 10 3 10 CRANKSHAFT REMOVAL 10 3 CRANKSHAF...

Page 102: ...10 CRANKCASE CRANKSHAFT 10 1 ZX SCOUT Torque 0 8 1 2kg m ...

Page 103: ...se 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 SPECIFICATIONS SC10AS Item Standard mm ServiceLimit mm Connecting rod big end side clearance 0 60 Connecting rod big end radial clearance 0 04 Crankshaft runout A B 0 15 0 10 SPECIAL TOOLS Crankcase puller Bear...

Page 104: ...ase 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 remove the crankshaft from the left crankcase Crankcase Puller Crankcase Puller ...

Page 105: ...ing the 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 Service Limit 0 04mm replace if over Universal Bearing Puller ...

Page 106: ...0mm replace if over 0 100mm replace if over 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 for cracks or other faults Play Play Radial Axial ...

Page 107: ... a new crankshaft bearing into the left crankcase Install the crankshaft into the left crankcase Bearing Outer Driver Handle A Bearing Outer Driver 37x40mm Bearing Driver Pilot 17mm Bearing Outer Driver Handle A Bearing Outer Driver 42x47mm Pilot 20mm Crankcase Assembly Collar Crankcase Assembly Tool ...

Page 108: ...LY Install the dowel pins and a new gasket to the crankcase mating surface Assemble the crankcase halves The distance between the right crankcase oil seal and crankcase surface is about 12 5 0 5 mm Dowel Pins Crankcase Assembly Tool Crankcase Assembly Tool ...

Page 109: ...10 CRANKCASE CRANKSHAFT 10 8 ZX SCOUT The distance between the left crankcase oil seal and crankcase surface is about 1 0mm Install and tighten the crankcase attaching bolts Oil Seal 1 0mm Bolts ...

Page 110: ..._____________________________________________ __________________________________________________________________________________ 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 11 FLOAT CHAMBER 11 8 ...

Page 111: ...11 CARBURETOR 11 1 ZX SCOUT ...

Page 112: ...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 getting to cylinder Clogged fuel cap vent Float level too low Clogged fuel filter Clogged fuel filter Clogged air cleaner Clogged air cleaner Bent kinked or restricted fuel line Engine idles roughly stal...

Page 113: ...rier Ö12 5 Remove the met in box Ö12 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 rubber seal Carburetor Cap Throttle Valve Rubber Seal Carburetor Cap Spring ...

Page 114: ...l the jet needle on the throttle 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 valve Carburetor Cap Throttle Valve Rubber Seal Throttle Cable Throttle Valve Spring Needle Retainer 2nd Notch STD Needle Clip Jet Needle Throttle Valve ...

Page 115: ...le cable free play Ö3 11 Idle speed adjustment Ö3 8 Install the met in box CARBURETOR REMOVAL Remove the met in box Ö12 4 Remove the air cleaner by removing the air cleaner band screw and attaching bolts Disconnect the fuel tube Loosen the drain bolt to drain fuel from the carburetor Disconnect the auto bystarter wire connector Remove the two carburetor lock nuts Groove Throttle Stop Screw Carbure...

Page 116: ...nals 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 If air cannot be blown into the hose clogged the auto bystarter is faulty Replace it with a new one Bolts ...

Page 117: ...nd blow the hose with mouth If air can be blown into the hose the auto bystarter is faulty and replace it with a new one AUTO BYSTARTER REMOVAL Remove the auto bystarter cover 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 Screws O ring Set Plate Bystarter Va...

Page 118: ... carburetor body until it bottoms Install the set plate and then tighten the two screws FLOAT CHAMBER Remove the two float chamber screws and the float chamber Remove the screw and O ring Remove the float pin float and float valve Screws Auto Bystarter Set Plate Screws Float Pin O ring Float ...

Page 119: ... JETS SCREWS REMOVAL Before removing the throttle stop screw or air screw record the number of rotations until it seats lightly Then remove them Remove the main jet and needle jet holder CARBURETOR PASSAGES CLEANING Blow compressed air through all passages of the carburetor body with an air gun Float Valve Float Seat Main Jet Throttle Stop Screw Air Screw ...

Page 120: ...d float pin Tighten the float screw securely FLOAT LEVEL INSPECTION Slightly tilt the carburetor and measure the float level with the float valve 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 Tighten the screws Main Jet Air Screw Throttle Stop Screw...

Page 121: ...STMENT Remove the met in box Ö12 4 Turn the air screw clockwise until it seats lightly and back it to the specification given Air Screw Opening 1 turns 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 the engine speed and make sure that the engine does...

Page 122: ...and gasket Remove the reed valve and gasket INSPECTION Check the reed valve for damaged or weak reeds Check the reed valve seat for cracks damage or clearance between the seat and reed Replace the valve if necessary INSTALLATION Install the reed valve in the reverse order of removal Bolts Intake Manifold Reed Stopper Reed Valve Seat Reeds ...

Page 123: ... 5 Remove the rear carrier Ö12 5 Disconnect the fuel tube and vacuum tube at the auto fuel valve Fuel Tank Cap Disconnect the fuel unit wire connector Remove the fuel tank mounting bolts and fuel tank Fuel Tank Inspect the fuel unit Ö16 2 Replace the fuel unit if necessary Ö16 2 Auto Fuel Valve Fuel Tube Vacuum Tube ...

Page 124: ...___ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FRAME COVERS __________________________________________________________________________________ SERVICE INFORMATION 12 2 FRAME COVERS REMOVAL 12 3 ...

Page 125: ...12 FRAME COVERS 12 1 ZX SCOUT ASSEMBLY DRAWING ...

Page 126: ...r Removal Handlebar front 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 carrier frame body cover right and left side rails battery Front tool box Front cover front right and left lower covers right and left side rails floor board ...

Page 127: ...taching the handlebar front cover Remove the handlebar front cover The installation sequence is the reverse of removal FRONT RIGHT LEFT LOWER 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 left lower covers Remove the front right and left lower cove...

Page 128: ...verse of removal BOTTOM COVER REMOVAL Remove the right and left side rails Ö12 3 Remove the front cover Ö12 3 Remove the front right and left lower covers Ö12 3 Remove the three bolts attaching each side of the bottom cover Remove 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...

Page 129: ...ar carrier Remove the rear carrier Remove the frame body cover The installation sequence is the reverse of removal 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 Bolts Rear Carrier Screws Screws Front Fender ...

Page 130: ...________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STEERINGHANDLEBAR FRONTWHEEL FRONT BRAKE FRONTSHOCKABSORBER FRONTFORK __________________________________________________________________________________ SERVICE INFORMATION 13 2 TROUBLESHOOTING 13 2 ST...

Page 131: ...13 STEERINGHANDLEBAR FRONTWHEEL FRONT BRAKE FRONTSHOCKABSORBER FRONTFORK 13 1 ZX SCOUT 3 3kg m 6 0kg m 2 7kg m 4 5kg m SERVICE INFORMATION ...

Page 132: ...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 brake disk or disk pad Excessively tightened steering stem top Worn brake bushing cone race Worn brake master cylinder piston oil seal Broken steering balls Clogged brake fluid line Insufficient tire pres...

Page 133: ...lever 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 cable and then remove the throttle pipe from the handlebar Remove the handlebar lock nut to remove the handlebar Bolts Bolts Bolts Throttle Cable INSTALLATION Brake Master Cylinder Throttle Pipe Ha...

Page 134: ...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 is the reverse of removal Install the rear brake lever holder Install the front brake master cylinder disk brake FRONT WHEEL REMOVAL Brake Master Cylinder Tab Groove Holders Throttle Cable ...

Page 135: ...sconnect 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 measure the runout The actual runout is of the total indicator reading Service Limit 0 2mm replace if over Speedometer Cable Check the wheel rim runout Service Limits Radial 2 0mm replace if over Axle Nut ...

Page 136: ...OCKABSORBER FRONTFORK 13 6 ZX SCOUT 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 Play Remove the wheel bearings and distance collar Radial Axial Dust Seal Play ...

Page 137: ...ng cavities with grease Drive in the left bearing Install the distance collar Drive in the right bearing Pilot 10mm Apply grease to the dust seal lip and install the dust seal Install the side collar Bearing Puller Grease Pilot 10mm Outer Driver 28x30mm Drive the bearing squarely with the sealed end facing out ...

Page 138: ...ove Connect the speedometer cable Torque 5 0 7 0kg m Groove Axle Nut Tab Side Collar HYDRAULIC BRAKE FRONT BRAKE Brake Fluid Replacement Air Bleeding Check the brake fluid level on level ground When operating the brake lever the brake reservoir cap must be tightened securely to avoid spill of brake fluid When servicing the brake system use shop towels to cover plastic parts and ...

Page 139: ... fluid to the brake reservoir Make sure to bleed air from the brake system Lower Limit Bleed Valve Brake fluid spilled on brake pads or brake disk will reduce the braking effect Clean the brake pads and brake disk with a high quality brake degreaser Warning Front Brake Caliper When bleeding be careful not to allow air in the brake reservoir flowing into the brake system When using a brake bleeder ...

Page 140: ... 2 0kg m Brake Disk Measure the brake disk thickness Service Limit 3 0mm Measure the brake disk runout Service Limit 0 3mm Front Brake Caliper Brake Pads BRAKE MASTER CYLINDER Removal First drain the brake fluid from the hydraulic brake system When servicing the brake system use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid When removi...

Page 141: ...aster 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 Bolts Spring Master Cylinder Main Piston Washer Snap Ring Inspection Measure the brake master cylinder I D Service Limit 12 75mm Brake Master Cylinder Inspect the master cylinder for scratch or crack ...

Page 142: ...ll the main piston spring and snap ring Install the rubber cover Install the brake lever During assembly the main piston and spring must be installed as a unit without exchange When assembling the piston soak the cups in brake fluid for a while Install the cups with the cup lips facing the correct direction Place the brake master cylinder on the handlebar and install the holder with up mark facing...

Page 143: ... 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 Ö13 10 Place a clean container under the brake caliper and disconnect the brake fluid pipe from the caliper Up Mark Bolts Disassembly Remove the brake caliper seat from the brake caliper Punch Mark Bolt Do not spill brake fluid on any ...

Page 144: ...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 Clean the oil seal groove with brake fluid Compressed Air Piston Oil Seal Check the piston for scratch or wear Measure the piston O D with a micrometer Service Limit 25 30mm Be careful not to damage t...

Page 145: ...d 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 silicon grease to the brake caliper seat pin and caliper inside Install the brake caliper seat Install the piston with its outer end 3 5mm protruding beyond the brake caliper Installation Install the ...

Page 146: ...aliper 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 Ö13 9 Bolts FRONT SHOCK ABSORBER REMOVAL Remove the front wheel Ö13 5 Remove the front shock absorber upper mount bolts Loosen the lower mount bolts to remove the front shock absorbers ...

Page 147: ... the front shock absorber and remove the shock absorber tube hex bolt and copper washer from the front shock absorber Front Shock Absorber Mount Bolt Circlip Use a vise to hold the front shock absorber tube and remove the damper from the shock absorber tube When holding the shock absorber tube place a shop towel under it and do not apply too much force Front Shock Absorber Dust Boot ...

Page 148: ...CKABSORBER ASSEMBLY Damper Damper Nut 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 front shock absorber spring with the loosely wound coils facing up Oil Seal Absorber Tube Damping Spring Front Shock Absorber Dust Seal Front Shock Absorber Spring Circlip ...

Page 149: ...he washer and socket 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 Damper Nut Front Shock Absorber Bolt Washer Circlips INSTALLATION Install the front shock absorbers onto the steering stem Install and tighten the front shock absorber upper mount bolts Tighten the lower mount bolts Dust Boot ...

Page 150: ...ng stem top cone 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 Front Shock Absorber Be careful not to lose the steel balls 26 on top race and 29 on bottom race BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race using a chisel Drive a new bottom cone race i...

Page 151: ...all races Bottom Cone Race Ball Race Remover Outer Driver 37x40mm Driver Handle A Be sure to drive the ball races into place completely 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 install the front fork ...

Page 152: ... 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 front wheel Ö13 8 Install the handlebar Ö13 4 Install the speedometer cable Check that the steering stem rotates freely without vertical play Top Cone Race Lock Nut Socket Wrench Lock Nut Wrench ...

Page 153: ...___________________________________________________________ 14 __________________________________________________________________________________ __________________________________________________________________________________ REARWHEEL REARBRAKE REAR SHOCKABSORBER __________________________________________________________________________________ SERVICE INFORMATION 14 2 TROUBLESHOOTING 14 2 REA...

Page 154: ...14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER 14 1 ZX SCOUT 4 5kg m 3 0kg m 11 0kg m ...

Page 155: ... 5 4 5kg m 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 TROUBLESHOOTING Rear wheel wobbling Bent rim Faulty tire Axle not tightened properly Soft rear shock absorber Weak shock absorber spring Poor brake performance Brake not adjusted properly Contaminated...

Page 156: ...ve the exhaust muffler Remove 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 apply SAE30 engine oil to the axle threads Then tighten the rear axle nut Torque values Rear axle nut 11 0 13 0kg m Rear Axle Nut Rear Axle Nut ...

Page 157: ...rake 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 REAR BRAKE DISASSEMBLY Remove the rear brake adjusting nut and disconnect the rear brake cable Remove the rear brake shoes Keep oil or grease off the brake linings Brake Arm Brake Shoes Adjusting Nut ...

Page 158: ...gine oil to the felt seal and install it to the brake cam Install the wear indicator plate Install the brake arm onto the brake cam Install and tighten the brake arm bolt Install the brake arm return spring Install the brake shoes Wear Indicator Plate Brake Arm Bolt Align the wide tooth of the wear indicator plate with the wide groove on the brake cam Brake Arm Brake Cam Grease Brake Arm Punch Mar...

Page 159: ...E REAR SHOCK ABSORBER 14 6 ZX SCOUT Install the brake arm pin Connect the brake cable and install the adjusting nut Install the rear wheel Ö14 3 Adjust the rear brake lever free play Ö3 4 Brake Arm Adjusting Nut Brake Arm Pin ...

Page 160: ...emove the rear shock absorber DISASSEMBLY Install the rear shock absorber compressor 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 Upper Mount Bolt Lower Mount Bolt Rear Shock Absorber Rear Shock Absorber Compressor Lock Nut Install the rear shock absorber lower joint into the rear shock abso...

Page 161: ...mage Measure the rear shock absorber spring free length Service Limit 232mm replace if below ASSEMBLY Assemble the rear shock absorber in the reverse order of disassembly Tighten the lock nut Torque 3 5 4 5kg m Spring Damper Damper Rod Rubber Install the shock absorber spring with loosely wound coils facing down Apply locking agent to the lock nut thread and then install and tighten the lock nut ...

Page 162: ...STALLATION 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 Ö12 5 Upper Mount Bolt Lower Mount Bolt ...

Page 163: ..._______________________________________________ __________________________________________________________________________________ 15 __________________________________________________________________________________ ELECTRICAL EQUIPMENT __________________________________________________________________________________ SERVICE INFORMATION 15 1 TROUBLESHOOTING 15 1 CHARGING SYSTEM 15 3 BATTERY 15 4...

Page 164: ...ard 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 187Ω Secondary coil with plug cap 6 99 10 21KΩ Ignition coil resistance Secondary coil without plug cap 3 24 3 96KΩ Pulser coil resistance 20 80 160Ω Ignition timing 15 5 2 BTDC 2000rpm TROUBLESHOOTING CHARGING SYSTEM No power Intermittent power Dead battery Loose battery cable connection...

Page 165: ...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 Starter motor won t turn Lack of power Fuse burned out Weak battery Weak battery Loose wire or connection Faulty ignition switch Foreign matter stuck in starter motor Faulty starter switch or pinion Fa...

Page 166: ...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 167: ...tery cover 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 battery positive cable Connect the charger negative cable to the battery negative cable Charging current Standard 0 4A Quick 4A Charging time Standard 5 hours Quick 0 5 hour After charging Open circ...

Page 168: ...ine gradually increase engine speed to test the output Position RPM Day Night 2500 1 3A min 1 0A min 6000 2 0A min 2 0A min Charging Limit Voltage 14 5 0 5V 8000rpm If the limit voltage is not within the specified range check the regulator rectifier A C GENERATOR CHARGING COIL INSPECTION Remove the met in box Ö12 4 Disconnect the A C generator connector Measure the resistances between the charging...

Page 169: ...istor B 5 6 6 2Ω REGULATOR RECTIFIER INSPECTION Remove the front cover Ö12 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 if the readings are not within the specifications in the table below Probe Probe A R B W C Y D G A R B W 3 10KΩ C Y 33 35K Ω D G 33 35K Ω Resis...

Page 170: ...15 ELECTRICAL EQUIPMENT 15 7 ZX SCOUT D Green IGNITION SYSTEM A C Generator Exciter Coil Ignition Coil Pulser Coil Ignition Switch CDI Unit Pulser Coil ...

Page 171: ...stance 20 0 153 0 187Ω Measure 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 21KΩ Measure the secondary coil resistance between the ignition coil terminal and the primary coil terminal as Figure B shown Resistance 20 without plug cap 3 24 3 96KΩ Figure B Figure A Ignition Coil Black Green ...

Page 172: ...COUT A C GENERATOR Exciter Coil Pulser Coil Inspection Remove the met in box Ö12 4 Disconnect the A C generator wire connector Measure the pulser coil resistance between the blue yellow wire and ground Resistance 20 80 160Ω Blue Yellow ...

Page 173: ...s Replace the CDI unit if the readings are not within the specifications in the table below Use the x KΩ range for the Sanwa Tester Use the x 100Ω range for the Kowa Tester Unit KΩ Probe Probe Black Yellow Black Red Black White Blue Yellow Green Black Yellow Black Red 1 10 Black White Blue Yellow 3 40 80 120 10 30 Green 2 10 10 30 Coupler CDI Unit Green Blue Yellow Black White Black Yellow Black R...

Page 174: ...15 ELECTRICAL EQUIPMENT 15 11 ZX SCOUT Starting System Battery Starter Relay Ignition Switch Starter Button Starter Button Starter Relay Starter Button Starter Morter ...

Page 175: ...terminal and the relay yellow red terminal to the battery negative terminal Check for continuity between the starter 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 the starter motor The installation sequence is the reverse of removal Starter Relay Yello...

Page 176: ...15 ELECTRICAL EQUIPMENT 15 13 ZX SCOUT Starter Motor STARTER MOTOR INSPECTION Connect a battery across the starter motor and check for its operation Starter Motor Battery Terminal Battery ...

Page 177: ..._______________________ __________________________________________________________________________________ __________________________________________________________________________________ 16 INSTRUMENT SWITCHES LIGHTS __________________________________________________________________________________ SERVICE INFORMATION 16 1 TROUBLESHOOTING 16 1 FUEL UNIT 16 2 OIL METER 16 3 SWITCHES 16 5 STOP SW...

Page 178: ...ficient 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 winker Motor oil indicator light winks Loose wire connection Light dims Broken wire Faulty ignition coil Faulty oil meter Wire or switch resistance too high Faulty regulator rectifier Fuel gauge poi...

Page 179: ...sure the resistance between the fuel unit wire terminals with the float at upper and lower positions Wire Terminals Upper Lower G Y W 33Ω 686Ω G L W 566Ω 53Ω Y W L W 600Ω 600Ω FUEL GAUGE INSPECTION Connect the fuel unit wire connectors and turn the ignition switch ON Check the fuel gauge needle for correct indication by moving the fuel unit float up and down Float Position Needle Position Upper F ...

Page 180: ...e oil meter float at the lower position Measure the resistances between the wire terminals as c and d shown in the left figure Wire Terminals Resistance Green Red Black 5 16Ω Green Black Oil Meter Operation Inspection Connect the oil meter wire connectors and turn the ignition switch ON Measure the resistance between the wire terminals with the float at upper position Green Red Black About 340Ω Re...

Page 181: ...he ignition switch 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 Ö12 3 Disconnect the ignition switch wire couplers Remove the two mounting bolts and remove the ignition switch The installation sequence is the reverse of removal Oil Indicator Light Ignition Swi...

Page 182: ...ue White Yellow Brown Pink Brown White Symbol HL CL 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 continuity between the wire terminals Color Light Blue Orange Gray Symbol R L WR R L L W Y Headlight Switch Br W P Br W L B L W Dimmer Switch O Gr SB Turn S...

Page 183: ... HORN SWITCH INSPECTION Check for continuity between wire terminals Push the horn button when measuring Color Light Green Black Symbol HO BAT2 FREE PUSH STOP SWITCH INSPECTION Remove the handlebar front cover Ö12 3 Disconnect the front and rear stop switch wire couplers Check for continuity between the wire terminals when the front rear brake lever is applied Y R G Starter Switch Lg B Horn Switch ...

Page 184: ... TURN SIGNAL LIGHT REPLACEMENT Remove the turn signal light shell and the bulb Replace with new ones TAILLIGHT STOPLIGHT REAR TURN 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 installation sequence is the reverse of removal Battery Horn Turn Signal Lig...

Page 185: ... three screws attaching the speedometer Remove the speedometer The installation sequence is the reverse of removal HEADLIGHT REMOVAL BULB REPLACEMENT Remove the handlebar front cover Ö12 3 Remove the bulb sockets and bulbs The installation sequence is the reverse of removal Bulb Sockets Speedometer cable Bulb Sockets The model adopts krypton gas bulb When installing do not directly touch the bulb ...

Page 186: ...____________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EVAPORATIVE EXHAUSTEMISSION CONTROLSYSTEM __________________________________________________________________________________ EXHAUST EMISSION CONTROL SYSTEM 17 1 EXHAUST MUF...

Page 187: ...ce the concentration of HC and CO 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 runs erratic at idle speed and Lack of power and high CO HO high fuel consumption 1 Clogged exhaust muffler 1 Clogged exhaust muffler 2 Faulty oxidizing catalytic convert...

Page 188: ...f removal The temperature of exhaust muffler is very high Be careful to avoid burns during working Lock Bolts Exhaust Muffler A large amount of unburned mixture flowing into the high heat catalytic converter will burn again and cause damage to the converter due to overheat Pay attention to the following Use 92 or 95 nonleaded gasoline only Leaded gasoline will cause catalytic converter failure Dur...

Page 189: ...D 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 muffler 100 50 Standard CO 3 0 5 HC 7000PPM max 4 If CO or HC exceeds the specified values adjust the carburetor air screw A S until CO and HC are within the specified standard values A S Opening 1 turns 5...

Page 190: ...more completely When the spent fuel charge is released into the exhaust system it is still hot enough to burn The system allows extra air into the exhaust system so that the spent fuel charge can continue to burn This continued burning action tends to burn up a great deal of the normally unburned gases as well as changing a significant portion of the poisonous carbon monoxide into harmless carbon ...

Page 191: ...KYMCO TECHNICAL INFORMATION 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 2 2 ...

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