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zx / scout 50 - Absolutely Scooters & Supply

1. 12 3 KYMCO 12 FRAME COVERS ZX I SCOUT 50 FLOOR BOARD REMOVAL Remove the rear carrier 12 5 Remove frame body cover 12 5 Remove right and left side rails 12 3 Remove the battery cover and battery Remove the four bolts attaching the floor board to remove the floor board The installation sequence 15 the reverse of removal When removing the battery first j Floor Board disconnect the battery negative cable ver ode Front Tool Box Bolt 1 1 5 1 and then the positive cable FRONT TOOL BOX REMOVAL Remove the rear carrier 12 5 Remove the frame body cover 12 5 Remove the floor board 12 3 Remove the front right and left lower covers 12 3 Remove the three bolts attaching the front tool box Remove the front tool box The installation sequence is the reverse of Front Tool Box removal S l N BOTTOM COVER REMOVAL 79 TEN Remove right and left side rails 12 3 1 1 d Remove the front cover 12 3 Remove front right and left lower covers _ UB 12 3 Remove the three bolts attaching each side of the bottom cover Remove the bottom cover The installation sequence 15 the reverse of removal Bottom Cover Met in Box Rubber Packing Oil Tank Cap MET IN BOX REMOVAL Open the seat Remove the two bolts two nuts and the center bolt attaching the met in box Remove th
2. 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 Limit 11 98mm replace if below Measure the piston to piston pin clearance Service Limit 0 03mm replace if over KYMCO 6 CYLINDER HEAD CYLINDER PISTON ZX SCOUT 50 PISTON RING INSPECTION Measure each piston ring end gap Service Limits Top Second 0 40mm replace if over Set each piston ring squarely into the cylinder using the piston and measure the end gap CONNECTING ROD SMALL END INSPECTION Install the piston pin and bearing in the connecting rod small end and check for excessive play Measure connecting road small end I D Service Limit 17 03mm replace if over ow lt Small End I D Measurement gt PISTON CYLINDER INSTALLATION First install the expander in the second ring piston groove TONGUE 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 it and should be cleaned 6 9 KO KYMCO 6 CYLINDER HEAD CYLINDER PISTON ZX SCOUT 50 Install a new cylinder gasket on the matin
3. NO Lubrication Points Lubriant Remarks Crankcase sliding amp movable parts JASO FC or C E 2 Cylinder movable parts JASO FC or APLTC 3 Transmission gear final gear SAE 90 J _ 4 Kick starter spindle bushing Grease Jooo _5 Drive pulley movable parts Grease oo gt 6 Starter pinion movable parts Grese 1 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 T E Front Rear Brake Lever Grease Engine Oil Engine Oil Throttle Cable Seat Lock 2 Grease Speedometer Gear Me Qum ur Brake Cam Front EE pet e uva Shock Absorber sn c KOF a Lower Mount A w LEM Jen m et T 3 Grease Bushings Pivot Rear Wheel Bearing Grease Brake Cam Anchor Pin Grease Main Stand Pivot Engine Oil Rear Brake Cable 2 10 KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 SC10AS WIRING DIAGRAM Er Ua HET A ae 1 TI GO KYMCO 2 GENERAL INFORMATION ZX I SCOUT 50 CABLE amp HARNESS ROUTING Rear Stop Switch Wire Front Stop Switch Wire Front Brake Reservoir Rear Brake Cable Throttle Cable eds Cable Front Brake Fluid Tube Ignition Switch Horn Regulator Rectifier Resistor Front Brake Fluid Tube Speedometer Cable 2 12 KYMCO 2
4. Oil Pump Control Cable Spark Plug C Remove the spark plug cap uus T 5 2 KYMCO 5 ENGINE REMOVAL INSTALLATION ZX I SCOUT 50 Rear Shock Absorber Lower Mount Bolt C PO Remove the rear brake adjusting nut and disconnect the brake cable from the crankcase Remove the rear brake cable clamp and rear brake cable Remove the cooling air tube band on the left crankcase cover and disconnect the cooling air tube Remove the rear 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 ENGINE HANGER BRACKET REMOVAL Remove the engine hanger bracket bolt and engine hanger bracket The installation sequence 15 the reserve of removal Torque 3 5 4 5kg m Engine Hanger Bracket Bolt KYMCO 5 ENGINE REMOVAL INSTALLATION ZX I SCOUT 50 Engine Hanger ENGINE HANGER BRACKET INSPECTION Inspect the stopper rubbers and bushings for damage and replace with new ones if necessary Stopper Rubbers Bushings ENGINE INSTALLATION Install the engine in the reverse order of removal Cables and wires should be routed properly 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 Throt
5. Rear shock absorber spring free length 49201 218 7 ELECTRICAL EQUIPMENT SC10AS 12V3AH Voltage 13 0_ 13 2V alter 4 Charging Standard 0 4A 5H current 4A 0 5H Secondary coil Ignition coil resistance 6 99 1021 0 Secondary without plug cap 324 3 96 0 Pulser coil resistance 20 80 1600 Ignition timing 15 5 2 BTDC2000rpm KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 TORQUE VALUES ENGINE Cylinder head bolt BF7x115 Clutch drive plate nut Clutch outer nut Drive face nut Oil check bolt Engine mounting bolt Engine hanger bracket bolt BF10x50 Exhaust muffler joint lock nut NC6mm Exhaust muffler lock bolt BF8x35 Spark plug Thread dia mm Handlebar lock nut 45 5 0 Flange bolt U nut Steering stem lock nut 8 0 12 0 Steering top cone race 0 5 1 3 Front axle nut 5 0 7 0 Flange U nut Rear axle nut 11 0 13 0 Flange U nut Rear brake arm bolt Flange nut Front shock absorber upper mount bolt 3 3 lower mount bolt 3 3 hex bolt Apply locking agent Front damper nut Front pivot arm bolt Flange screw U nut Rear shock absorber upper mount bolt Flange nut lower mount bolt lower joint nut Torque specifications listed above are for important fasteners Others should be tightened to standard torque values below STANDARD TORQUE VALUES SH bolt 8mm Flange 6mm bolt Smm bolt nut 45 Smm screw 6mm bolt nut HE 6mm screw SH bolt 8mm bolt nut 8 6mm flange bolt nu
6. Torque values Rear axle nut 11 0 13 0kg m 14 3 14 REAR WHEEL REAR BRAKE REAR QD KYMCO SHOCK ABSORBER ZX SCOUT 50 REAR BRAKE Remove the rear wheel gt 14 3 Inspect the rear brake drum Measure the rear brake drum I D Service Limit 95 5mm replace if over BRAKE LINING INSPECTION Measure the brake lining thickness Service Limit 2 0mm replace if below Keep oil or grease off the brake linings Brake Arm Brake Shoes REAR BRAKE DISASSEMBLY Remove the rear brake adjusting nut and disconnect the rear brake cable Remove the rear brake shoes Adjusting Nut 14 4 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER Remove the brake arm bolt to remove the brake arm wear indicator plate and felt seal Remove the brake cam REAR BRAKE ASSEMBLY Apply grease to the anchor pin and brake shoe moving parts Apply grease to the brake cam and install it Apply engine oil to the felt seal and install it to the brake cam stall the wear indicator plate Align the wide tooth of the wear indicator plate with the wide groove on the brake cam stall the brake arm onto the brake cam Align the punch mark on the brake arm with the scribed line on the brake cam Install and tighten the brake arm bolt Install the brake arm return spring Install the brake shoes 14 5 KYMCO ZX I SCOUT 50 Brake Arm Bolt Wear Indicator Plate Brake Arm Brake Cam Grease Wear
7. and shown in the left figure Wire Terminals Green Red _ Black 5 169 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 3400 F Ligh 16 3 KYMCO ZX I SCOUT 50 Retainer t ON KYMCO 16 INSTRUMENT SWITCHES LIGHTS ZX I SCOUT 50 Oil Indicator Light Move the oil meter float up and down to see 1f the oil indicator light will go out and SWITCHES IGNITION SWITCH INSPECTION Remove the front cover gt 12 3 Disconnect the ignition switch wire couplers and check for continuity between the wire terminals 112 1 i Ignition Switch Coupler Bolts IGNITION SWITCH REPLACEMENT Remove the front cover gt 12 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 16 4 GO KYMCO 16 INSTRUMENT SWITCHES LIGHTS ZX I SCOUT 50 HEADLIGHT SWITCH INSPECTION Remove the handlebar rear cover gt 12 3 Disconnect the headlight switch wire coupler and check for continuity between wire terminals symbol HL CL TL RE Headlight Switch DIMMER SWITCH INSPECTION Check for continuity between wire terminals C Dimmer Switch TURN SIGNA
8. Service Limit 232mm replace if below ASSEMBLY Assemble the rear shock absorber in the reverse order of disassembly 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 Tighten the lock nut Torque 3 5 4 5kg m 14 8 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER INSTALLATION Install the rear shock absorber Install the rear shock absorber upper mount bolt and then install the lower mount bolt Torque Upper Mount Bolt 3 5 4 5kg m Lower Mount Bolt 24 3 0kg m Install the frame body cover gt 12 5 14 9 i WS 2 ZX I SCOUT 50 Upper Mount Bolt EN 4 Lower Mount Bolt KYMCO 15 ELECTRICAL EQUIPMENT ZX I SCOUT 50 ELECTRICAL EQUIPMENT SERVICE 15 1 TROUBLESHOOTING 15 1 CHARGING SYSTEM sss eene 15 3 D quus 15 4 IGNITION SYSTEM EE 15 7 STARTING 6 85 22 9 4 15 11 15 0 KYMCO 15 ELECTRICAL EQUIPMENT ZX I SCOUT 50 SERVICE INFORMATION GENERAL INSTRUCTIONS It is not necessary to check the battery electrolyte or fill with distilled water Remove the battery from the motorcycle for charging Do not remove the electrolyte cap Do not quick charge the battery Quick charging should only be
9. 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 at the specified rpm the ignition timing is correct if mark on the flywheel aligns with the index mark on the crankcase within 2 Ignition Timing 15 5 2 BTDC 2000rpm 3 7 3 INSPECTION ADJUSTMENT ENGINE BODY At High and Low Speeds The engine must be warm for accurate idle speed adjustment Adjust the idle speed to the specified range by turning the throttle stop screw and air screw Idle Speed 2100 100rpm Throttle Stop Screw Air Screw Air Cleaner Remove the air cleaner cover by removing Screws the six air cleaner cover screws Remove air cleaner element 3 8 3 LUBRICATION SYSTEM Wash the air cleaner element in detergent oil squeeze out and allow to dry Never use gasoline or organic vaporable oil with acid or alkali for washing After washing soak the element in clean engine oil SAE 15W 407 and squeeze out excess oil Reinstall the element Wash Squeeze out Soak in oil Squeeze out and dry excess oil Cylinder Compression Warm up the engine before compression test Remove the spark plug and insert compression gauge Open the throttle valve fully and push the starter button for 7 8 seconds to test the compression Compression 11
10. CRANKSHAFT REMOVAL Attach the crankcase puller on the left crankcase and remove the crankshaft from the left crankcase 10 3 dC KYMCO 10 CRANKCASE CRANKSHAFT ZX SCOUT 50 Remove the remaining bearing on the crankshaft side using the universal bearing puller Universal Bearing Puller CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 6mm replace if over Measure the connecting rod big end radial clearance at two points in the X and Y directions Service Limit 0 04mm replace if over 10 4 KYMCO 10 CRANKCASE CRANKSHAFT ZX I SCOUT 50 Measure the crankshaft runout 0 150mm me 100mm replace if over replace if over Check the crankshaft bearings for excessive play The bearings must be replaced if they are noisy or have excessive play Radial CRANKSHAFT INSTALLATION Wash the crankshaft in cleaning solvent and then check for cracks or other faults 10 5 dC KYMCO 10 CRANKCASE CRANKSHAFT ZX SCOUT 50 Drive new crankshaft bearing into the Bearing Outer Driver Handle right crankcase Bearing Outer Driver 37x40mm Bearing Driver Pilot 17mm Bearing Outer Driver Handle A Drive a new crankshaft bearing into the left crankcase Bearing Outer Driver 42x47mm Pilot 20mm Crankcase Assembly Collar Za a Install the crankshaft into the left crankcase 2 1 2 Crankcase Assembly T
11. Hold the connector body when connecting or disconnecting it Do not pull the connector wire ts dl E gt n pr le pm a Check if any connector terminal is bending protruding or loose KYMCO ZX SCOUT 50 The connector shall be inserted completely B If the double connector has a lock lock it at the correct position Check if there is any loose wire Before connecting a terminal check for damaged terminal cover or loose negative terminal Check the double connector cover for proper coverage and installation F E i 1 m fn mag 1 2 i ann a m 1 pu T E my n un uem i n 3 T B Insert the terminal completely Check the terminal cover for proper coverage Do not make the terminal cover opening face up Fu n CA E g r a ade ER fe un 2 xL d o TAN Lisa Lu Secure wire harnesses to the frame with their respective wire bands at the designated locations Tighten the bands so that only the insulated surfaces contact the wire harnesses M L di rm X 2 GENERAL INFORMATION After clamping check
12. Lever Looseness abnormal Cable noise and damage Brake Drum to lining System clearance Indicator type Front 110 mm Rear 110 mm Service Limits Front 111 mm Rear 111 mm Tee 1 1 50 1 75 rider kg cm kg cm Tire 120 70 120 70 Size 12 12 3 1 KYMCO 3 INSPECTION ADJUSTMENT ZX ISCOUT 50 Inspection amp Maintenance Item Judgment Standards Remarks Ist Every 6 Every 12 month months months Tire cack and damage O Jo lo f Groove Depth Tire groove and mane Pl pee EE Imbedded objects gravel etc Torque Values Front axle nut Axle nut looseness 50 7 0kg m Rear axle nut 11 0 13 0kg m Rim runout at rim end Check wheel rim rim edge and spoke plate for damage 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 Connecting parts loose ness and arm damage eee o Assembly parts loose ness abnormal noise Cw operation fo fo fo Transmis Oil level Rear wheel sion case Oil check bolt hole transmis at lower hole edge sion case Battery Terminal connection Loose connection and Wires damage dC KYMCO 3 INSPECTION ADJUSTMENT ZX ISCOUT 50 Frequency Inspection amp Maintenance Item dn Judgment Standards Remarks st very
13. connector Faulty starter relay Starter motor turns normally Seized cylinder Broken or shorted starter motor cable Faulty starter pinion Hard to turn O Probable Cause Faulty starter pinion Stopped e Starter relay shorted or stuck closed 2 26 KYMCO 3 INSPECTION ADJUSTMENT ZX ISCOUT 50 p INSPECTION ADJUSTMENT INSPECTION AND MAINTENANCE SCHEDULE 3 1 BRAKE SOTEM n 3 4 MOVING DEVIC DP 3 5 DAMPING DE VI Le 3 6 POWER DRIVES DEM m 3 6 PONNI 3 7 ENN 3 8 MMR 3 11 KYMCO 3 INSPECTION ADJUSTMENT ZX ISCOUT 50 INSPECTION AND MAINTENANCE SCHEDULE Note 1 means time for inspection 2 means regular replacement for the specified parts This inspection and maintenance schedule is based upon average riding conditions Machines subjected to serve use or ridden in unusually dusty areas require more frequent servicing Frequency Inspection amp Maintenance Item ma p Judgment Standards Remarks Prende st very very month months months Steering 1l handlebar pets 0 Susp ension Check for front fork Check steering stem Front pivot installation fork Check steering stem Check front fork pivot for looseness and abnormal noise Front rear brake lever Free play free play 10 20mm Brake Lever Brake lever operation o Brake performance
14. pump control cable by loosening the control cable lock nut and turning the adjusting nut After adjustment tighten the lock nut n d y Lock Nut Adjusting Nut Reference tip alignment within 1mm of index mark on open side 1s acceptable However the aligning mark on the control lever must never be on the closed side of the index mark otherwise engine damage will occur because of insufficient lubrication 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 3 10 3 LUBRICATION SYSTEM FUEL SYSTEM Throttle Grip Free Play Measure the throttle grip free play Free Play 2_ 6mm Lock Nut If the throttle grip free play does not fall within the specified range adjust by loosening the lock nut and turning the adjusting nut Adjusting Nut OTHERS LIGHTS Headlight Adjust the headlight beam by loosening the headlight adjusting bolt and moving the adjusting bolt forward and backward to a proper position Tighten the adjusting bolt Headlight Adjusting Bolt 3 11 KYMCO 4 LUBRICATION SYSTEM ZX ISCOUT 50 M LUBRICATION SYSTEM SERVICE 4 2 TROUBLESHOOTING sees 4 2 OIL PUMP REMOVAL 4 3 OIL PUMP INSPECTION essere 4 3 OIL PUMP 4 4 OIL
15. 15 13 KYMCO 16 INSTRUMENT SWITCHES LIGHTS ZX I SCOUT 50 INSTRUMENT SWITCHES LIGHTS SERVICE INFORMA TION ed 16 1 TROUBCESHOO CIN Le 16 1 PUE 0 16 2 MENER 16 3 JAG EE 16 5 STOP SWITCH INSPECTION HORN mm 16 6 BULB REPLACEMENT Te IEEE EE IHE NN 16 7 INSTRUMEN 16 8 16 0 16 INSTRUMENT SWITCHES LIGHTS SERVICE INFORMATION GENERAL INSTRUCTIONS KYMCO ZX I SCOUT 50 Wires should be connected to other wires of the same color Couplers must be connected to other couplers of the same color All plastic plugs have locking tabs that must be released before disconnecting and must be aligned when reconnecting After installation of each switch a continuity check must be performed TROUBLESHOOTING Lights do not come on when ignition switch is ON Burned bulb Faulty switch Broken or shorted wire Fuse burned out e Weak battery Poorly connected wire Faulty winker Light dims Faulty ignition coil Wire or switch resistance too high Faulty regulator rectifier Headlight does not change when dimmer switch is turn to Hi or Lo Faulty or burned bulb Faulty dimmer switch 16 1 Motor oil indicator light does not come on when motor oil is insufficient Fuse burned out Dead battery Faulty ignition switch Faulty instrument Faulty oil meter
16. A C GENERATOR CHARGING COIL INSPECTION Remove the met in box gt 12 4 Disconnect the A C generator connector Measure the resistances between the charging coil terminals white green and lighting coil terminals yellow green Resistances 02 120 Lighting coil_lyellow green 0 3 1 00 Refer to 7 3 for A C generator removal 15 5 PN ZX I SCOUT 50 A C Generator Connector KYMCO 15 ELECTRICAL EQUIPMENT ZX I SCOUT 50 RESISTOR INSPECTION Remove the frame front cover gt 12 3 Measure the resistance between the resistor B pink wire and ground Measure the resistance between the resistor green black wire and ground Resistances Resistor A 9 9 10 50 Resistor 5 6 620 Resister Resister B REGULATOR RECTIFIER INSPECTION Remove the front cover gt 12 3 Bolt Disconnect the regulator rectifier wire coupler and remove the bolt to remove the m regulator rectifier Measure the resistances between the terminals Replace the regulator rectifier 1f the readings are not within the specifications in the table below Coupler Regulator Rectifier A Red C Yellow B White D Green 15 6 dC KYMCO 15 ELECTRICAL EQUIPMENT ZX I SCOUT 50 IGNITION SYSTEM Ignition Coil CDI Unit Pulser Coil A C Generator Exciter Coil Ignition Switch L Y Ignition Coil Pulser CDI Unit JA
17. EINAL ee 9 CRANKCASECRANKSHAFT gassene 10 pvr 11 EKAME COVERS een 12 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT 13 REAR WHEEL REAR SHOCK ABSORBER 14 15 16 EVAPORATIVE EXHAUST EMISSION CONTRAL SYSTEM 17 1 0 1 SPECIFICATIONS SPECIFICATIONS Overall width mm 690 Net weight kg Seating capacity 2 riders 110kg Gross weight kg 120 70 12 ires 120 70 12 Ground clearance mm Braking distance m Tm GOkm h Initial speed Km h a On 1940 TUE Gasoline 2 stroke motor oil Fuel type Compression pressure 11 5kg cm po Port Open lees l 255 Close Intake ZX 50 Lubrication oil capacity 0 80 liter Air cleaner type amp No Fuel capacity liter Plunger type Carburetor Piston dia mm 14 CDI electromagnetic Ignition Venturi dia mm Ignition system type Ignition timing F mark 155 x ve 2 e NO 3 B Spark NGK BR8HSA plug 0 0 0 7 12V3AH Power transmission gear clutch Spark plug gap mm 3 m lt Z Power to transmission gear Reduction ratio of power to transmi
18. GENERAL INFORMATION ZX SCOUT 50 Throttle Cable Speedometer Cable Front Brake Fluid Tube Rear Brake Cable Wire Harness Speedometer Cable Front Brake Fluid Tube E 2 13 KYMCO 2 GENERAL INFORMATION ZX I SCOUT 50 Fuel Unit Ignition Coil PT Oil Tube Uo n T CDI Unit f Oil Tank Cap 7 N Wire Harness Battery Fuel Filter Ignition Coil Starter Relay 2 14 GO KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 Fuel Unit Fuel Tank Cap Vacuum Tee Oil Tube Oil Pump Ignition Coil 2 15 KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment Probable Cause Check if fuel reaches carburetor by loosening drain screw Empty fuel tank D Fuel reaches Fuel does not Q Clogged float valve Faulty auto fuel valve Faulty spark plug Fouled spark plug Faulty CDI unit Faulty A C generator Broken or shorted ignition coil Broken or shorted exciter coil Faulty ignition switch Remove plug and install it into spark plug cap to test spark by connecting it to engine ground OGSAGD Spark jumps Weak or no spark Test cylinder compression Burned or worn cylinder piston Faulty reed valve Blown cylinder head gasket Leaking crankcase Faulty crankcase oil seal Normal Low or no compression compression OG OB Start engine by follow ing normal start
19. Motor oil indicator light winks Loose wire connection Broken wire Faulty oil meter Fuel gauge pointer does not register correctly Disconnected wire or connector Broken wire Faulty float Faulty fuel unit Faulty instrument Fuel gauge pointer fluctuates or swings Loose wire connection e Faulty fuel unit Faulty instrument KO KYMCO 16 INSTRUMENT SWITCHES LIGHTS _ZX SCOUT 50 FUEL UNIT Fuel Unit REMOVAL Remove the frame body cover gt 12 5 Disconnect the fuel unit wire connectors Turn the fuel unit retainer counterclockwise to remove it Remove the fuel unit INSPECTION Remove the fuel unit Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions G YW 6860 G L W 5660 Y W_ L W 6000 6000 L W FUEL GAUGE INSPECTION Connect the fuel unit wire connectors and turn the ignition switch Check the fuel gauge needle for correct indication by moving the fuel unit float up and down Noodle Position F E Empty 16 2 16 INSTRUMENT SWITCHES LIGHTS INSTALLATION The installation sequence is the reverse of removal OIL METER INSPECTION Remove the met in box gt 12 4 Remove frame body cover 12 4 Disconnect the oil meter wire connectors and remove the oil meter Keep the oil meter float at the lower position Measure the resistances between the wire terminals as
20. Surface and Brake Pad Wear Check the brake disk surface for scratch Check if the brake pad wear 15 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 Brake Master Cylinder Fluid Level Inspection Turn the steering handlebar upright and check if the front brake fluid level is within the specified limits through the front brake master cylinder check hole Brake Lining BEIGE Limit Mark Brake Disk TRU Me DOE MON E EU A oe aaae 472 M ER Brake Master Cylinder 3 4 3 LUBRICATION SYSTEM MOVING DEVICE TIRES Tire Pressure Check the tire pressure Tire pressure should be checked when tires are cold Tire Pressure one rider Front 1 50 kg cm _ Rear 1 75 kg cm __ Tire Size Front 120 70 12 Rear 120 70 12 Axle 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 1 0 13 0kg m Wheel Rim Spoke Plate Damage Check the wheel rim and spoke plate for Axle Nut wear or damage and measure the rim runout Rear Wheel 3 INSPECTION ADJUSTMENT DAMPING DEVICE SHOCK ABSORBERS Oil Leak Damage Fully apply the front brake and check
21. air bubbles in the brake fluid Then tighten the bleed valve Repeat these steps until the brake system is free of air Front Brake Caliper Brake Fluid Refilling Add DOT 3 brake fluid to the brake reservoir When bleeding be careful not to allow air in the brake reservoir flowing into the brake system When using a brake bleeder follow the manufacturer s instructions Never use dirty or unspecified brake fluid or mix different brake fluids be cause it will damage the brake system Make sure to bleed air from the brake system 13 9 SIEFRINGHANDI FBARFRONTWHETI FRONT BRAKEFRONTSHOCK ABSORBERIFRONTFORK ZX SCOUT 50 Pad Pin Brake Pad Disk Replacement The brake pads must be replaced as a set to ensure the balance of the brake disk Remove the two bolts attaching the brake caliper Remove the brake caliper Remove the brake pad pins to remove the brake pads Front Brake Caliper Brake Pads Install the brake pads in the reverse order of removal Tighten the brake pad pin bolts Torque 1 5 2 0kg m Keep grease or oil off the brake pads to avoid brake failure Brake Disk Measure the brake disk thickness Service Limit 3 0mm Measure the brake disk runout Service Limit 0 3mm 13 STEERINGHANDLEBARFRONT WHEELFRONT KYMCO BRAKEFRONTSHOCKABSORBERFRONTFORK 7X SCOUT 50 BRAKE MASTER CYLINDER Brake Master Cylinder Removal F
22. 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 8 14 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY DRIVEN PULLEY FACE BEARING REPLACEMENT Check the needle bearings in the driven face and replace them if they have excessive play damage or abnormal noise Drive the inner bearing out of the driven pulley face 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 Pack all bearing cavities with 5 0 5 60 grease Specified grease 230 Heat resistant grease 8 15 KYMCO ZX SCOUT 50 Outer Bearing Bearing Outer Driver 37x40mm p 8 KICK STARTER DRIVE PULLEY C KYMCO CLUTCH DRIVEN PULLEY ZX SCOUT 50 Drive in a new needle bearing into the Bearing Driver Pilot driven face with the mark facing up f y i Outer Driver 24x26mm Driven Pulley Oil Seal CLUTCH DRIVEN PULLEY ASSEMBLY First install the movable driven face onto the driven face Then install the guide roller pins O rings and a new oil seal O rings Guide Roller Pin Install the seal collar 9 16 8 KICK STARTER DRIVE PULLEY O KYMCO CLUTCH D
23. cable Holders Brake Master Cylinder The installation sequence 1s the reverse of removal Install the rear brake lever holder Install the front brake master cylinder disk brake 13 4 SIEFRINGHANDI FBARFRONTWHETI FRONT BRAKEFRONTSHOCKABSORBER FRONTFORK ZX SCOUT 50 FRONT WHEEL Axle pus REMOVAL Jack the motorcycle front wheel off the ground Remove the speedometer cable set screw and disconnect the speedometer cable Remove the front axle nut and pull out the axle Remove the front wheel Remove the brake panel side collar Speedometer Cable INSPECTION Set the axle in V blocks and measure the runout The actual runout is _ of total indicator reading Service Limit 0 2mm replace if over 13 5 BRAKFEFRONTSHOCK ABSORBER FRONT FORK Check the wheel rim runout Service Limits 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 Radial DISASSEMBLY Dust Seal Remove the dust seal SIEFRINGHANDI FBARFRONTWHETI FRONT ark BRAKFEFRONTSHOCK ABSORBERFRONTFORK Bearing Puller Remove the wheel bearings and distance collar Pilot 10mm ASSEMBLY Grease m 2 D ee gt Pilot 10mm Pack all bearing cavities with grease Drive in the left bearing Install the distance collar D
24. etc when reassembling B When tightening bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally B After reassembly check all parts for proper tightening and operation B When two persons work together pay attention to the mutual working safety Disconnect the battery negative terminal When servicing the motorcycle be sure to before operation use special tools for removal and Wh k Suse laco en using a spanner or other tools make sure not to damage the motorcycle surface Sa m After disassembly clean removed parts m E Lubricate sliding surfaces with engine oil points tasteners and lines tor proper before reassembly connection and installation When connecting the battery the positive terminal must be connected first After connection apply grease to the battery terminals Terminal caps shall be installed securely 2 2 2 GENERAL INFORMATION B If the fuse is burned out find the cause and repair it Replace it with a new one according to the specified capacity E fir asy confirm at d Lag ll S Lu B Lat un RE After operation terminal caps shall be installed securely m When taking out the connector the lock on the connector shall be released before operation
25. races Outer Driver 37x40mm Driver Handle A Drive in new ball races Be sure to drive the ball races into place completely 13 21 SIEFRINGHANDI FBARFRONTWHETI FRONT BRAKEFRONTSHOCK ABSORBERIFRONTFORK ZX SCOUT 50 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 Apply grease to the top cone race and install it Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely Check that the steering stem rotates freely without vertical play Top Cone Race Lock Nut Socket Wrench Install the steering stem lock nut and tighten it while holding the top cone race F Torque 8 0 12 0kg m Install the front wheel 13 8 Install the handlebar 13 4 Install the speedometer cable Lock Nut Wrench 14 REAR WHEEL REAR BRAKE REAR KYMCO ___ SHOCK ABSORBER ZXISCOUT 50 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER SERVICE INFORMATION sse 14 2 5 22 2 14 2 REAR WHEEL 14 3 REAR EEE 14 4 REAR SHOCK 14 7 14 0 14 REAR WHEEL REAR BRAKE REAR KYMCO SHOCK ABSORBER 2ZX SCOUT 50 11 0kg m 14 1 14 REAR WHEEL
26. the front shock absorber upper mount bolts Loosen the lower mount bolts to remove the front shock absorbers T n m A 8 Front Shock Absorber Mount Bolt Circlip LEFT FRONT SHOCK ABSORBER DISASSEMBLY Remove the dust boot Remove the circlip Dust Boot Use a vise to hold the front shock absorber and remove the shock absorber tube hex bolt and copper washer from the front shock absorber Front Shock Absorber 13 17 BRAKFEFRONTSHOCK ABSORBER FRONT FORK 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 shop towel under it and do not apply too much force Measure the front shock absorber spring free length Service Limit Right 200mm Lett 200mm FRONTS HOCK ABSORBER ASSEMBLY Damper Damper Nut Dust Seal Front Shock Absorber Circlip Spring Oil Seal Damping Spring Absorber 1e Tube 13 18 SIEFRINGHANDI FBARFRONTWHETI FRONT E harpen BRAKE FRONTSHOCK ABSORBERFRONTFORK 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 Damper Nut Front Shock Absorber Use a vise to hold the front shock absorber Tighten the hex bolt Ap
27. very month months months Performance and abnormal noise Conditions at low and high Body speeds Exhaust smoke nm 1 Oil level indicator Indicator light comes on when oil is Lubrica insufficient Engine system oe Fuel leakage loq FS and auto bystarter Fuel sre FTTTT T clogging Fuellevel _ O eese operation Lights amp Winke Winking action dirt and damage Buzzer amp ti Steering Lock pe Rearview Mirror Rearview amp earview mirror position Reflector amp Counter 9 l1 w fo 1 Exhaust muffler performance Body amp Frame Looseness and damage 1O Check if the abnormal conditions occur again Jo fo i Remove carbon deposits on Others combustion chamber breather hole and exhaust muffler 3 3 3 INSPECTION ADJUSTMENT BRAKE DRUM SHOE Brake Shoe Wear Replace the brake shoes if the arrow on the brake arm aligns with reference mark A on the brake panel when the brake is fully applied Brake Drum Wear Damage Check the brake drum appearance for damage Check if the brake lining wear 1s 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
28. 5kg cm If the compression is low check for the following Leaking cylinder head gasket e Worn piston cylinder If the compression is high it indicates that carbon deposits have accumulated on the combustion chamber and the piston head LUBRICATION SYSTEM Oil Filter Cleaning Disconnect tube at the oil pump side and allow oil to drain into a clean container Remove the tube clip at the oil tank side and disconnect the oil tube Remove the oil filter Oil Filter 3 INSPECTION ADJUSTMENT Clean the oil filter screen with compressed air Install the oil filter in the reverse order of removal and fill the oil tank with specified oil up to the proper level Bleed air from the oil pump and oil lines Connect the oil tubes securely Install the tube clip at the oil tank side and also install the clip to the lower oil tube that goes to the oil pump Check for oil leaks Filter Screen Oil Pump Condition Adjust oil pump control cable after the throttle grip free play 15 adjusted Open the throttle valve fully and check that the index mark on the pump body aligns with the aligning mark on the oil pump control lever Reference tip alignment within 1mm of index mark on open side is acceptable Start and idle the engine then slowly open the throttle to increase engine rpm and check the operation of the oil pump control lever If adjustment is necessary adjust the oil
29. EEDING u 21 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 oil lines or pump have been removed or there is air in the oil lines Oil Pump OIL INLET LIN FOIL PUMP BLEEDING Fill the oil tank with recommended oil Place a shop towel around the oil pump Disconnect the oil inlet line from the oil pump and clip it Fill the oil pump with oil by squirting clean oil through the joint About 3cc Fill the oil line with oil and connect it to the oil pump Bleed air from the oil inlet line first then bleed air from the oil outlet line OIL OUTLET LINE BLEEDING 1 Disconnect the oil outlet line and bend it into U shape Force air out 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 I minute bleed air from the oil inlet line and oil pump Oil Outlet Line Never run the engine in a closed area Do not increase the engine speed at will Tube 4 5 KYMCO 4 LUBRICATION SYSTEM ZX ISCOUT 50 OIL TANK OIL TANK REMOVAL Remove the rear carrier 12 5 Remove frame body cover 12 5 Remove the oil meter connector Remove the two bolts attaching the oil tank Disconnect the oil inlet line Drain the oil inside the oil tank into a c
30. INSTRUCTIONS When working with gasoline keep away from sparks and flames Note the locations of O rings when disassembling and replace them with new ones during assembly All cables fuel lines and wires must be routed and secured at correct locations Bleed air from the oil lines whenever they are disconnected SPECIFICATIONS enturi dia Identification number Float level Main jet Slow jet Air screw opening 1 Idle speed 2100 100rpm Throttle grip free play 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 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 stalls or runs poorly Rich mixture Incorrect idle speed Clogged air cleaner Faulty float valve Ignition malfunction Intake air leaks Float level too high Compression too low Fuel contaminated Clogged air jets Incorrectly adjusted air screw Faulty reed valve ncorrect float level Clogged fuel jets 11 2 KYMCO 11 CARBURETOR ZX I SCOUT 50 THROTTLE VALVE DIS ASSEMBLY Remove the rear carrier 12 5 Remove the met in box 12 4 Loosen the carburetor cap and remove the throttle valve Carburetor Cap Throttle Valve Disco
31. Indicator Plate Punch Mark Brake Arm 14 REAR WHEEL REAR BRAKE REAR ABSORBER ZX SCOUT 50 Install the brake arm pin Brake Arm Connect the brake cable and install the adjusting nut Install the rear wheel gt 14 3 Adjust the rear brake lever free play 3 4 Adjusting Nut Brake Arm Pin 14 6 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER ZX I SCOUT 50 REAR SHOCK ABSORBER prest REMOVAL Remove the rear carrier 5 12 5 Remove met in box gt 12 4 Remove the air cleaner case 5 2 Remove the rear shock absorber upper and lower mount bolts to remove the rear shock absorber Lower Mount Bolt Rear Shock Absorber Rear Shock Absorber Compressor DISASSEMBLY Install the rear shock absorber compressor as the figure shown Install the rear shock absorber lower joint into the rear shock absorber compressor Compress the rear shock absorber spring Rear Shock Absorber Remover Lock Nut Loosen the lower joint lock nut Remove the lower joint Remove the lock nut rubber and damper 14 7 14 REAR WHEEL REAR BRAKE REAR O KYMCO SHOCK ABSORBER ZX SCOUT50 Spring INSPECTION Inspect the damper rod for bending or damage Inspect the damper for oil leaks Inspect the damper rubber for deterioration or damage Damper Damper Rod Rubber Measure the rear shock absorber spring free length
32. KYMCO ZX I SCOUT 50 PREFACE This Service Manual describes the technical feature s and servicing procedures for KYMCO SCOUT 50 In this manual many illustrations and drawings are used to help servicemen have better understanding Section 2 contains the service precautions for all operations and troubleshooting stated in this manual Read them carefully before starting any operation Section 3 describes the inspection adjustment procedures safety rules and service information for each part starting from periodic maintenance Sections 4 through 16 give instructions for disassembly assembly and inspection of lubrication system engine fuel system and electrical equipment Section 17 is the maintenance and inspection directions for the evaporative exhaust emission control system Most sections start with an assembly or system illustration and troubleshooting for the section The subsequent pages give detailed procedures for the section KWANG YANG MOTOR CO LTD OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION MARCH 2000 KYMCO 1 SPECIFICATIONS SED _ TABLE OF CONTENTS PET NINNI 1 GENERAL INFORMATION avse 2 INSPECTION ADJUSTMEN Bussene 3 LUBRICATION SYSE Nasse 4 ENGINE 5 4 4 5 CYLINDER HEAD CYLINDER PISTON eesesvevevevevevesevenenenenenenenenenesnen 6 AC GENER 7 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY 8
33. L Remove the drive belt cooling air tube connector circlip Remove the nine left crankcase cover bolts left crankcase cover and dowel pins Inspect the left crankcase cover seal rubber for damage or deterioration Bolt Left Crankcase Cover Kick Starter Spindle KICK STARTER SPINDLE REMOVAL Remove the kick lever from the kick starter spindle Remove the circlip and washer from the kick starter spindle Washer Circlip Slightly rotate the kick starter spindle to remove the kick starter driven gear together with the friction spring Friction Spring Kick Starter Driven Gear 8 KICK STARTER DRIVE PULLEY O KYMCO CLUTCH DRIVEN PULLEY ZX SCOUT 50 Kick Starter Spindle Remove the kick starter spindle and return spring from the left crankcase cover Remove the kick starter spindle bushing Spindle Return Spring KICK STARTERSPINDLE 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 Spindle Bushing washer Friction Spring Check the kick starter driven gear for wear or damage Check the friction spring for wear or damage Kick Starter Driven Gear 8 KICK STARTER DRIVE PULLEY O KYMCO CLUTCH DRIVEN PULLEY Inspect the kick starter spindle and driven gear forcing parts for wear or damage KICK STARTER INSTALLATION Install the kick starter spindle bu
34. L SWITCH INSPECTION Check for continuity between the wire terminals RJ LAR Turn Signal Switch 16 5 dC KYMCO 16 INSTRUMENT SWITCHES LIGHTS ZX I SCOUT 50 STARTER SWITCH INSPECTION Check for continuity between wire terminals Push the starter button when measuring Yellow Red Symbol FREE PUSH Starter Switch HORN SWITCH INSPECTION Check for continuity between wire terminals Push the horn button when measuring Light Green Horn Switch STOP SWITCH INSPECTION Remove handlebar front cover gt 12 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 16 6 KYMCO 16 INSTRUMENT SWITCHES LIGHTS ZX I SCOUT 50 HORN INSPECTION Horn Battery Remove the frame front cover gt 12 3 Disconnect the horn wire couplers The horn is normal if it sounds when a 12V battery 15 connected across the horn wire terminals FRONT TURN SIGNAL LIGHT REPLACEMENT Remove the turn signal light shell and the bulb Replace with new ones Turn Signal Light Bulb TAILLIGHT S TO PUGHT REAR TURN Taillight Shell 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 i
35. LEY CLUTCH DRIVEN PULLEY SERVICE INFORMA UM 8 2 FROL OLIN vvs 8 2 FICE SIREN 8 3 Bison Pipe 8 7 DEI BJ 8 9 RER EINING 8 11 CLUTCH DRIVEN PULLEY vn 8 12 3 0 8 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY ZXISCOUT 50 MODEL SC10AS KA 5 VAN Torque Torque 3 5 4 5kg m 8 1 8 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY SERVICE INFORMATION GENERAL INSTRUCTIONS ZX SCOUT 50 Avoid getting grease and oil on the drive belt and pulley faces SPECIFICATIONS TORQUE VALUES Drive face nut 3 5 4 0kg m Clutch outer nut 3 5 45kg m Clutch drive plate nut 5 0 6 0kg m SPECIAL TOOLS Lock nut wrench 39mm Clutch spring compressor Bearing outer driver 37x40mm One way clutch puller TROUBLESHOOTING Engine starts but motorcycle won t move Worn drive belt Broken ramp plate Worn or damaged clutch lining Engine stalls or motorcycle creeps Broken clutch weight spring Savice Limit mm Universal holder Lock nut socket wrench 32mm Bearing driver pilot 17mm Outer driver 24x26mm Poor performance at high speed or lack of power Worn drive belt Weak driven face spring Worn weight roller Faulty driven face 8 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY ZX I SCOUT 50 KICK STARTER LEFT CRANKC AS CO VER REMO VA
36. PUMP BLEEDING 4 5 OIL TANK 041444440 0 44 4 6 4 0 ZX ISCOUT 50 KYMCO 4 LUBRICATION SYSTEM LUBRICATION SYSTEM 4 1 KYMCO 4 LUBRICATION SYSTEM ZX ISCOUT 50 SERVICE INFORMATION GENERAL INSTRUCTIONS Use care when removing and installing the oil pump not to allow dust and dirt to enter the engine and oil line Do not attempt to disassemble the oil pump Bleed air from the oil pump if there is air between the oil pump and oil line If oil is disconnected refill the oil line with motor oil before connecting it SPECIFICATIONS Recommended Motor Oil SAE20W20 2 stroke Motor 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 line pump not properly adjusted insufficient oiling Air in oil line Faulty oil pump Oil not flowing out of tank to engine e Clogged oil tank cap breather hole Clogged oil filter 4 LUBRICATION SYSTEM OIL PUMP REMOVAL Do not allow foreign matters to enter the crankcase Before removing the oil pump clean the oil pump and crankcase surfaces Remove met in box 12 4 Dis
37. Q2 Bent rim 3 Loose axle nut Misaligned front and rear wheels Bent front fork KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 POOR SUSPENSION PERFORMANCE Symptom Probable Cause EEE EE ENER TE Front and rear tire pressures are normal D Weak shock spring Shock damper oil leaking D Bent fork tube or shock rod OO MUR 2 Fork slider and tube binding TTE Fork tube and spring binding Fork slider and tube binding POOR PERFORMANCE Symptom Probable Cause Adjust brake according to standards Worn brake linings Index mark on brake 2 Worn brake cam contacting area panel aligns with wear on indicator arrow brake shoes Worn brake cam Worn brake drum be Worn brake linings Foreign matter on brake linings Rough brake drum contacting area Brake squeaks Brake performance 15 Expanding poor Brake Hydraulic Brake OVO 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 or grease on brake disk Deformed brake disk Leaking brake fluid tube ONONO 2 23 KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 OIL METER 1 Motor oil indicator light does not come on when there is no motor oil Ignition swi
38. REAR BRAKE REAR KYMCO SHOCK ABSORBER ZX SCOUT 50 SERVICE INFORMATION SPECIFICATIONS Standard mm Rear brake drum I D Rear brake lining thickness Rear shock absorber spring free length TORQUE VALUES Rear axle nut 11 0_ 13 0kg m Rear shock absorber upper mount bolt 3 55 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 brake linings Worn brake linings Worn brake shoes at cam contacting area Worn brake cam Improper engagement between brake arm and wear indicator plate 14 2 14 REAR WHEEL REAR BRAKE REAR QD KYMCO SHOCK ABSORBER ZX SCOUT 50 REAR WHEEL Rear Axle Nut REMOVAL Remove the two exhaust muffler joint lock nuts Remove the two exhaust muffler lock bolts Remove the exhaust muffler Remove the rear axle nut to remove the rear wheel INSPECTION Measure the rear wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over Rear Axle Nut INSTALLATION Install the rear wheel and apply SAE30 engine oil to the axle threads Then tighten the rear axle nut
39. RIVEN PULLEY ZX SCOUT 50 Set the driven pulley driven face spring and clutch assembly onto the clutch spring compressor Compress the tool and install the 39mm drive plate nut Tighten the 39mm nut to the specified torque Torque 5 0 6 0kg m Clutch Driven Pulley 1 uw i CLUTCH DRIVEN PULLEY INSTALLATION Install the drive belt on the clutch driven pulley and then install the clutch driven pulley onto the drive shaft i fi 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 8 6 Universal Holder 8 17 KYMCO 9 FINAL REDUCTION ZX SCOUT 50 FINAL REDUCTION 2 5 0 6 18 3 9 2 9 2 FINAL REDUCTION 9 3 FINAL REDUCTION 1 4 9 3 FINAL REDUCTION ASSEMBLY ccc RII 9 6 9 0 ZX SCOUT 50 KYMCO 9 FINAL REDUCTION 9 1 dC KYMCO 9 FINAL REDUCTION ZX SCOUT 50 SERVICE INFORMATION Specified Oil 5 90 At disassembly 0 12 liter At change 0 1 liter SPECIAL TOOLS Bearing remover set 12mm Bearing remover set 15mm Crankcase assembly collar Crankcase assembly shaft Bear
40. Spark Plug Generator 15 7 KYMCO 15 ELECTRICAL EQUIPMENT ZX I SCOUT 50 IGNITION COIL INSPECTION Continuity Test Remove met in box 12 4 Measure the resistance between the ignition coil primary coil terminals Resistance 20 0 153 0 1870 Measure the secondary coil resistance between the spark plug cap and the primary coil terminal as Figure A shown Resistance 20 C with plug cap 6 99 10 21KQ Figure B Figure A Ignition Coil Measure the secondary coil resistance between the ignition coil terminal and the primary coil terminal as Figure B shown Resistance 20 C without p lug cap 3 24 3 96KQ Green Black 15 8 4O KYMCO 15 ELECTRICAL EQUIPMENT ZX I SCOUT 50 Blue Yellow A C GENERATOR Exciter Coil Pulser Coil Inspection Remove the met in box gt 12 4 Disconnect the A C generator wire connector Measure the pulser coil resistance between the blue yellow wire and ground Resistance 20C 80 1600 15 9 KYMCO 15 ELECTRICAL EQUIPMENT ZX I SCOUT 50 CDI UNIT INSPECTION Remove the battery cover Disconnect the CDI coupler and remove the CDI unit CDI CIRCUIT INSPECTION CDI Unit Measure the resistance between the terminals Black Black Black Replace the CDI unit if the readings are not White Yellow within the specifications in the table below Green Blue Yellow Use the range for the Sanwa Tester
41. Use 1000 range for the Kowa Tester Probe Black Black Black Blue ha Red Bue Green Black Yellow 15 10 KYMCO 15 ELECTRICAL EQUIPMENT ZX I SCOUT 50 Starting System Starter Button Starter Button Batte Starter Relay Starter Relay WY Y R G Y R W R Starter Button Start Battery VSAH 15 11 KYMCO 15 ELECTRICAL EQUIPMENT ZX I SCOUT 50 Starter Relay STARTER RELAY INSPECTION Remove the battery cover Disconnect the starter relay coupler and then remove the starter relay P 5 m 1 3B E E at 52 Ti a v i Hy Red Yellow Red Connect the starter relay green yellow terminal to the 12V battery positive terminal and the relay yellow red terminal to the battery negative terminal Check for continuity between the starter relay red and red white terminals The relay is normal if there is continuity Red White Green Y ellow Bolts 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 Motor 15 12 15 ELECTRICAL EQUIPMENT SCOUT 50 STARTER MOTOR INSPECTION Connect battery across the starter motor and check for its operation Starter Motor p Battery Terminal Battery 1
42. Y REMOVAL Remove the battery cover Disconnect the battery cables Remove the bolt and battery bracket Remove the battery The installation sequence is the reverse of removal BATTERY CHARGING OPEN CIRCUIT VOLTAGE INSPECTION Remove the battery cover and disconnect the battery cables Measure the voltage between the battery terminals Fully charged 13 0V_ 13 2V Undercharged 12 3V max Battery i CHARGING METHOD Connect the charger positive cable to the battery positive cable Connect the charger negative cable to the battery negative cable Power Lamp Green Charging Lamp Red Charging current Standard 0 4A Quick 4 Charging time Standard 5 hours Quick 0 5 hour After chargng Open circuit voltage 12 8V min 15 4 15 ELECTRICAL EQUIPMENT PERFORMANCE TEST Warm up the engine Remove the floor mat and battery cover Stop the engine and open the fuse box Disconnect the wire lead from the fuse terminal Connect an ammeter between the wire lead and fuse terminal as shown Connect the battery positive terminal to the voltmeter positive probe and battery negative terminal to the voltmeter negative probe Start the engine gradually increase engine speed to test the output 2500 6000 Charging Limit Voltage 14 5 0 5 V 8000rp m If the limit voltage 15 not within the specified range check the regulator rectifier
43. ZX SCOUT 50 Main Jet Throttle Stop Screw Air Screw Float Pin 11 10 KYMCO 11 CARBURETOR ZX I SCOUT 50 CARBURETOR INSTALLATION Check the carburetor insulator and O ring for wear or damage Install the carburetor and insulator onto the intake manifold and tighten the two lock nuts Connect the fuel tube and auto bystarter wire connector Insulator Install the carburetor cap 11 4 Install the air cleaner onto the carburetor and tighten the band screw Carburetor Cap Install the met in box 12 4 AIR SCREW ADJUSTMENT Remove the met in box 12 4 Turn the air screw clockwise until it seats lightly and back it to the specification given Air Screw Opening l 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 not miss or run erratic If the adjustment of the air screw within the range of turn makes no difference to the engine performance check other related items Throttle Stop Screw 11 11 dC KYMCO 11 CARBURETOR ZX SCOUT 50 REED VALVE REMOVAL Remove the rear carrier Remove the frame body cover Remove the four intake manifold bolts and gasket Remove the reed valve and gasket Intake Manifold Reed Stopper INSPECTION Check the r
44. ak or dead battery Signals operate Signals dim remain Faulty ignition switch properly on or don t Loose or disconnected Remove fuel unit and operate connector check operation of Broken wire harness pointer by moving float up and down Pointer does not D Faulty float Check operation of pointer by opening and shorting fuel unit terminal on wire harness side Pointer does not Pointer moves D Broken or shorted fuel move unit wire Check connectors for proper connection Loose or disconnected Fault connector E connector D Broken or shorted wire in fuel gauge 2 Pointer fluctuates or swings Ignition switch ON Inspection Adjustment Probable Cause Check battery circuit by operating turn signals and horn D Burned out fuse Weak or dead battery Faulty ignition switch Loose or disconnected connector Broken wire harness Signals operate properly Signals dim remain on or don t 1 Remove fuel unit and check operation of pointer by moving float up and down Pointer does not move Poor contact in fuel unit Move float up and down rapidly 1 round sec to check the operation of pointer Pointer moves in Pointer does not Insufficient d 1 accordance with move in accord fuel icient damping 01 float ance with float tuel gauge Check connectors for proper connection connector D Broken or shor
45. al noisy piston Leaking cylinder head gasket Worn cylinder and piston Loose spark plug Worn piston pin or piston pin hole Worn stuck or broken piston and piston rings Worn connecting rod small end bearing Worn or damaged cylinder and piston Compression too high overheating or knocking Abnormal noisy piston rings Excessive carbon build up in cylinder head Worn stuck or broken piston rings or on piston head Worn or damaged cylinder KYMCO 6 CYLINDER HEAD CYLINDER PISTON ZX I SCOUT 50 Spark Plug Cap CYLINDER HEAD REMOVAL Remove the rear carrier Remove the frame body cover 12 5 Remove the spark plug cap Remove the three bolts attaching the fan cover to remove the fan cover Remove the two joint lock nuts on the front of the exhaust muffler and then remove the two exhaust muffler lock bolts Remove the bolt attaching the engine hood to remove the engine hood The installation sequence 15 the reverse of removal When installing the exhaust muffler first tighten the two nuts on the front and then tighten the two bolts Remove the spark plug Remove the cylinder head bolts and the cylinder head LE de 1 E Li Vi 1 1 4 7 uw Loosen the bolts diagonally in 2 or 3 Ra i 5 times TG Gg Remove the cylinder head gasket 6 3 KYMCO 6 CYLINDER HEAD CYLINDER PISTON ZX I SCOUT 50 C
46. carburetor spark plug cap to test O ring spark by connecting it to engine ground Faulty or fouled spark plug en CDI unit Weak or inter Faulty A C generator mittent spark Faulty ignition coil Broken or shorted high Remove auto bystarter tension wire connecting wire and Faulty ignition switch check if bypass fuel line is clogged D Broken auto bystarte Not clogged Clogged wire Connect auto bystarter Faulty auto bystarter wire to battery Wait for 5 minutes then connect a hose to fuel enriching circuit and then blow the hose with mouth Clogged Not clogged 2 20 KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Probable Cause Check ignition timing D Faulty CDI unit Correct timing Incorrect timing Loose A C G stator Faulty A C generator Check auto fuel valve for fuel supply D Empty fuel tank Fuel flows freely Fuel flow Clogged fuel tube or restricted filter Q Clogged charcoal canister Check carburetor jets for clogging Not clogged Clogged D Clean and unclog Remove auto bystarter connecting wire and check if bypass fuel line is clogged Not clogged Clogged Broken auto bystarter wire Q Faulty auto bystarter Connect auto bystarter wire to battery Wait for 5 minutes then connect hose to fuel enriching circuit and then blow the hose with mout Clogged N
47. case cover bolts and left crankcase cover 8 3 Hold the clutch outer with the universal holder and remove the 14mm clutch outer nut and clutch outer Clutch Outer Clutch Outer Nut iw nd ZU JE ES Raichet Drive Face Hold the drive pulley with the holder and remove the drive face nut A Remove the starting ratchet S 5 Remove the drive pulley face e I gt gt b Drive Face Nut 8 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY ZX SCOUT 50 Clutch Driven Pulley Remove the drive belt from the clutch driven pulley DRIVE BELT INSTALLATION Turn the driven pulley clockwise and lift it up to expand the drive belt groove and then install new drive belt Drive Belt Drive Face Nut Drive Pulley Face Drive Belt Set the drive belt on the drive pulley Install the drive pulley face starting ratchet 7 and washer then tighten the drive face nut Bf sg Torque 3 5 4 0kg m When installing drive face nut make sure that the tooth spaces of the drive pulley face and starting ratchet align with the teeth of the crankshaft Starting Ratchet Washer 8 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY ZX SCOUT 50 DRIVE PULLEY ee ME REMOVAL Hold the drive pulley with the holder and remove the drive face nut Remove the starting ratchet washer and drive pulley fac
48. connect the oil pump control cable from the pump body Disconnect the oil inlet line from the oil pump Then disconnect the oil outlet line Before disconnecting the oil line clip the oil line to avoid oil flowing out and then plug the oil line after it is disconnected Remove the oil pump control cable plate bolt and copper washer Remove the oil pump from the crankcase OIL PUMP INSPECTION Remove the oil pump and inspect the following 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 Do not disassemble the oil pump which cannot be used after disassembly 4 3 KYMCO ZX ISCOUT 50 Oil Outlet Line Oil Pump p ut Control Cable Control Cable plate Ee O ring Control Lever Pinion KO KYMCO 4 LUBRICATION SYSTEM ZX ISCOUT 50 OIL PUMP INSTALLATION Lubricate the O ring with grease or engine before installation Make sure that the oil pump is inserted into the crankcase Apply molybdenum disulfide or grease to the pump pinion Install the pump onto the crankcase Install the pump control cable plate Connect the oil inlet line and oil outlet line properly Connect the oil pump control cable Bleed air from the oil pump Control Cable 4 4 dC KYMCO 4 LUBRICATION SYSTEM ZX ISCOUT 50 OIL PUMP BL
49. cover Install the brake lever coma 13 12 SIEFRINGHANDI FBARFRONTWHETI FRONT ark harpen BRAKFEFRONTSHOCK ABSORBERFRONTFORK Place the brake master cylinder on the Punch Mark handlebar and install the holder with mark facing up Be sure to align the punch mark with the holder joint First tighten the upper bolt and then tighten the lower bolt Torque 1 0 1 4kg m Install the brake fluid pipe with the attaching bolt and two sealing washers Install the handlebar covers 12 3 Fill the brake reservoir with recommended brake fluid to the upper limit and bleed air according to the method stated in 13 9 BRAKE CALIPER FRONT Removal Remove the brake caliper 13 10 Place a clean container under the brake caliper and disconnect the brake fluid pipe from the caliper Do not spill brake fluid on any coated surfaces 13 13 BRAKFEFRONTSHOCK ABSORBER FRONT FORK Brake Caliper Seat Disassembly Remove the brake caliper seat from the brake caliper Remove the piston from the brake caliper If necessary use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratch or wear and replace if necessary Compressed Air Piston Oil Seal Push the piston oil seal outward to remove it Clean the oil seal gro
50. done in an emergency Charge the battery according to the charging current and time specified on the battery When charging check the voltage open voltage with an electric tester When replacing the battery do not use a traditional battery SPECIFICATIONS SCIOAS 12V3AH 13 0 132V Battery Charging Standard 0 4A 10H current 4A 0 5H Spark plug NGK BR8HSA Spark plug gap 06 0 7mm 0 153 0 1870 Secondary coil Ignition coil resistance with dius can 6 99 10 21KQ2 Secondary coil without plug cap 3 24 3 96 Pulser coil resistance 20 C 80 1602 15 5 2 BTDC 2000rp Ignition timing TROUBLESHOOTING CHARGING SYSTEM No power Intermittent power Dead battery Loose battery cable connection Disconnected battery cable Loose charging system connection Fuse burned out Loose connection or short circuit in ignition sy stem Faulty ignition switch Loose connection or short circuit lighting sy stem Low power Charging system failure Weak battery Loose broken or shorted wire or connector Loose battery connection Faulty regulator rectifier Charging system failure Faulty A C generator Faulty regulator rectifier 15 1 15 ELECTRICAL EQUIPMENT IGNITION SYSTEM No spark at plug Faulty spark plug Poorly connected broken or shorted wire Between A C generator and CDI unit Between CDI unit and ignition coil Between CDI unit and igniti
51. e MOVABLE DRIVE FACE DISASSEMBLY Remove the movable drive face and drive pulley collar from the crankshaft Remove the ramp plate 8 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY ZX SCOUT 50 Remove the weight rollers Weight Roller MOVABLE DRIVE FACE INS PEC TION Check each weight roller for wear or damage Measure each roller O D Service Limit 12 4mm replace if below L Movable Drive Face DRIVE PULLEY INSTALLATION Install the drive pulley collar and movable drive face onto the crankshaft lt Ej P 2 4 PR Drive Pulley Collar 9 10 8 KICK STARTER DRIVE PULLEY EO KYMCO _ CLUTCHVDRIVENPULLEY ZX SCOUT 50 Install the drive belt on the crankshaft Install the drive face starting ratchet and washer then tighten the 12mm drive face nut Torque 3 5 4 0kg m Keep grease or oil off the drive belt and drive pulley faces Drive Pulley Face STARTER PINION REMOVAL Remove the left crankcase cover 8 3 Remove the drive pulley 8 9 Remove the starter pinion EM Starter Pinion Shaft Forcing Parts 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 r
52. e oil tank cap and rubber packing Remove the met in box The installation sequence 15 the reverse of removal Do not allow flames or sparks near the working area Bolt Bolts Nuts 12 FRAME COVERS FRAME BODY COVER REMOVAL Remove met in box 12 4 Remove the three bolts attaching the rear carrier Remove the rear carrier Remove the frame body cover The installation sequence is the reverse of removal 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 Screws Screws Front Fender 12 5 13 STFERINGHANDLEBARFRONTWHEELFRONT KYMCO BRAKEFRONTSHOCK ABSORBER FRONTFORK ZX SCOUT 50 BE STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK ENTEN ORM NN re 13 2 TROUBEESHOOTIN 5 13 2 STERN INNB EE 13 3 FRONT VEL 13 5 FRONT BRAKE DISK 2 7 1 12 13 9 FRONT SHOCK ABSORBER 13 17 FRONT TORE hhv 13 20 13 0 ZX SCOUT 50 KYMCO STEERING HANDLEBARFRONTWHEEL FFRONT BRAKE FRONTSHOCK ABSORBER FRONT FORK 13 13 1 STEERINGHANDLEBARFRONTWHEEL FRONT BRAKEFRONTSHOCK ABSORBER FRONT FORK SERVICE INFORMATION SPECIFICATIONS Standard mm Axle shaft runout S 2 Front wheel im runout i dt 0 _ Axa 20 2 3 111 ront brake drum I D 110 r
53. each wire to make sure it 15 secure Do not squeeze wires against the weld or its clamp x a After clamping check each harness to make sure that it is not interfering with any moving or sliding parts ma i JA 6 z r bh m When fixing the wire harnesses do not make it contact the parts which will generate high heat lt Don t touch Route wire harnesses to avoid sharp edges or corners Avoid the projected ends of bolts and screws Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws 8 a p A T SS X ZX SCOUT 50 Route harnesses so they are neither pulled tight nor have excessive slack T 7 WA M EL Fia 8 I 3 AE 2 Fi m gt m d Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner B When rubber protecting cover is used to protect the wire harnesses 1t shall be installed securely Do not break the sheath of wire B fa wire or harness 15 with a broken sheath repair by wrapping it with protective tape or replace it ue um Pm ES P he ar E e B When installing other parts do not press or squeeze the wires 2 GENERAL INFORMATION After routing check t
54. eed valve for damaged or weak reeds Check the reed valve seat for cracks damage or clearance between the seat and reed Replace the valve if necessary Reeds Reed Valve Seat INSTALLATION Install the reed valve in the reverse order of removal 11 12 11 CARBURETOR FUEL TANK REMOVAL Remove met in box 12 4 Remove frame body cover 12 5 Remove the rear carrier 12 5 Disconnect the fuel tube and vacuum tube at the auto fuel valve Disconnect the fuel unit wire connector Remove the fuel tank mounting bolts and fuel tank Inspect the fuel unit 16 2 Replace fuel unit if necessary 16 2 KYMCO ZX SCOUT 50 Fuel Unit Fuel Tank Cap Fuel Tank a Fuel Tube Vacuum Tube KYMCO 12 FRAME COVERS ZX I SCOUT 50 FRAME COVERS SERVICE INFORMATION 12 2 FRAME COVERS REMOVAL seen 12 3 12 0 KYMCO 12 FRAME COVERS ZX SCOUT 50 ASSEMBLY DRAWING 12 1 KYMCO 12 FRAME COVERS ZX SCOUT 50 SERVICE INFORMATION When removing frame covers use care not to pull them by force because the cover joint claws may be damaged Items Related for Removal Handlebar front cover Handlebar rear cover 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 r
55. emoval Starter Pinion 8 11 8 KICK STARTER DRIVE PULLEY EO KYMCO CLUTCH DRIVEN PULLEY zZX SCOUT50 CLUTCH DRIVEN PULLEY Clutch Outer 14mm Clutch Outer Nut d iw CLUTCH DRIVEN PULLEY REMO VAL Remove the drive pulley 8 9 Hold the clutch outer with the universal holder and remove the 14mm clutch outer nut Remove the clutch outer Universal Holder Clutch Driven Pulley 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 Spring Compressor 8 12 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY ZXISCOUT 50 Remove the seal collar Pull out the guide roller pins from the driven pulley and then remove the O rings and oil seal from the driven pulley CLUTCH DRIVEN PULLEY INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit 107 5mm replace if below 8 13 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY ZXISCOUT 50 Check the clutch shoes for wear or damage Measure the clutch lining thickness Service Limit 2 0mm replace if below Measure the driven face spring free length Service Limit 82 6mm replace if below Check the driven face
56. esin Washer 9 FINAL REDUCTION ZX SCOUT 50 After installation fill the transmission case with the specified oil Place the motorcycle its main stand on level ground Check the sealing washer for wear or damage Specified Gear Oil SAE90 Oil Capacity at disassembly 0 12 liter at change 0 1 liter Install and tighten the 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 Drain Bolt Oil Check Bolt Hole Filler KYMCO 10 CRANKCASE CRANKSHAFT ZX SCOUT 50 CRANKCASE CRANKSHAFT 10 2 10 2 CRANKCASE 5 10 3 CRANKSHAFT 1 10 3 CRANKSHAFT INSPECTION 10 4 5 10 5 CRANKCASE ASSEMBLY 10 7 10 0 KYMCO 10 CRANKCASE CRANKSHAFT ZX I SCOUT 50 Torque 0 8 1 2kg m 10 1 KYMCO 10 CRANKCASE CRANKSHAFT ZX I SCOUT 50 SERVICE INFORMATION GENERAL INSTRUCTIONS This section covers crankcase separation to service the crankshaft The following parts must be removed before separatin
57. et Do not pry between the cylinder and crankcase or strike the fins PISTON REMOVAL Remove the piston pin clip to remove the piston pin and piston Piston Pin Piston Do not damage or scratch the piston Do not apply side force to the connect ing rod when removing the piston pin Place clean shop towels in the crank case to keep the piston pin clip from falling into the crankcase Piston Pin Clip Spread each piston ring and remove by lifting it up at a point just opposite the gap Remove the expander 6 6 KYMCO 6 CYLINDER HEAD CYLINDER PISTON ZX SCOUT 50 CYLINDER PISTON INSPECTION Check the cylinder and piston for wear or damage Clean carbon deposits from the exhaust port area Be careful not to damage the cylinder inside wall Measure the cylinder bore at three levels of A B and C in both X and Y directions 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 KYMCO 6 CYLINDER HEAD CYLINDER PISTON ZX I SCOUT 50 Mark Nuts The cylinder has an mark or no mark on it When replacing the cylinder with new one use cylinder having the same mark as the old one Measure the piston O D at a point Smm from the bottom of the piston skirt Service Limit 38 90mm replace if below
58. exhaust muffler is very high Be careful to avoid burns during working INSPECTION 1 Inspect the exhaust muffler and joint for damage or crack Replace if necessary 2 Inspect the exhaust muffler joint packing collar for deformation or damage Replace if necessary INSTALLATION 1 Install the exhaust muffler in the reverse order of removal 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 During riding do not turn the ignition switch OFF to avoid a large amount of unburned mixture flowing into the exhaust muffler Faulty ignition system or fuel system will cause overheat and damage to the catalytic converter ZX SCOUT 50 Exhaust Muffler Joint Lock Nut Exhaust Muffler Lock Bolts 17 2 17 EVAPORATIVE EXHAUST EMISSION KYMCO CONTROL SYSTEM ZX 50 EXHAUST EMISSION RELATED SYSTEM INSPECTION Clean or replace the air cleaner Clean and adjust the carburetor Inspect the auto bystarter system Clean and inspect the spark plug Inspect the ignition system EXHAUST EMISSION TEST AND ADJUSTMENT 2 3 Start the engine and warm up for several minutes Engine surface temperature 50 60C 100 Adjust the idle speed to 2000 100rpm Co
59. g surface between the cylinder and crankcase Cylinder Gasket Ring Pins Make sure that the ring end gaps are aligned with the piston ring pins in the ring grooves Lubricate the cylinder inside and piston rings with engine oil and install the piston into the cylinder while compressing the piston rings Be careful not to damage the piston Install the cylinder head Torque 1 5_ 1 7kg m Install the exhaust muffler and tighten the exhaust muffler joint lock nuts Torque 10 1 4kg m Tighten the exhaust muffler lock bolts Torque 3 0 3 6kg m Install the frame covers 6 10 KYMCO 7 A C GENERATOR ZX SCOUT 50 A C GENERATOR DE RV ICE INFORMATION eee 7 2 NO GENERATOR REMOVAL ne 7 3 A C GENERATOR INSTALLATION HII 7 4 7 0 ZX SCOUT 50 KYMCO 7 A C GENERATOR 0 8 1 2kg m 0 6 1 0kg m _ 1 2kg m Torque 0 8 KYMCO 7 A C GENERATOR ZX SCOUT 50 SERVICE INFORMATION GENERAL INSTRUCTIONS All A C generator maintenance and inspection can be made with the engine installed Refer to Section 15 for A C generator inspection TORQUE VALUE Flywheel nut 3 5 4 0kg m SPECIAL TOOLS Flywheel puller Universal holder 7 A C GENERATOR A C GENERATOR REMOVAL 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 re
60. g the crankcase Engine Section 5 Driven pulley Section 8 Carburetor Section 11 A C generator Section 7 Oil pump Section 4 Cylinder head cylinder Section 6 Reed valve Section 11 When the left crankcase must be replaced remove the following part in addition to the above Final reduction removal Special tools must be used for crankshaft and crankcase 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 Service Limit mm Connecting rod big end side clearance Connecting rod big end radial clearance Crankshaft runout A B me 0 15 0 10 X SPECIAL TOOLS Crankcase puller Bearing outer driver handle A Universal bearing puller Bearing outer driver 42x47mm Crankcase assembly collar Bearing driver pilot 20mm Crankcase assembly tool Bearing outer driver 37x40mm Bearing driver pilot 17mm TROUBLESHOOTING Abnormal engine noise Excessive crank journal bearing play Excessive crankpin bearing play Excessive transmission bearing play 10 2 KYMCO 10 CRANKCASE CRANKSHAFT ZX I SCOUT 50 CRANKCASE SEPARATION Remove the crankcase attaching bolts Attach the crankcase puller on the right crankcase and remove the right crankcase from the left crankcase Crankcase Puller
61. hat the wire harnesses are not twisted or kinked Wire harnesses routed along with handlebar should not be pulled tight have excessive slack or interfere with adjacent or surrounding parts in all steering positions When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions z hv SX eet j j E a Pr When rust is found on a terminal remove the rust with sand paper or equivalent before connecting Remove the rest 2 3 KYMCO ZX I SCOUT 50 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 D Engine Oil Grease Apply grease for lubrication T Use special tool Special x Caution V Warning 12 3 Refer to page 12 3 KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 SERVICE INFORMATION ENGINE Cyinderheadwapage gt om Cylinderto pistonclearmce om Movable driven fee op Connecting rod big end side ckarmce lt Connecting rodbigend radial clearance O oo Crankshaftrmout AB 1 1 14mm 35 2100 100rpm 2 6 KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 Standard mm Service Limit mm
62. ight and left side rails battery Front tool box Front cover front right and left lower covers right and left side rails floor board 12 2 12 FRAME COVERS Front Cover FRAME COVERS REMOVAL FRONT COVER REMOVAL Remove the bolt attaching the front cover Remove the two screws on the back of the front cover Remove the front cover downward Disconnect the headlight wire connector The installation sequence 15 the reverse of removal 7 Bolt Screw _ Handlebar Rear Cover During removal be careful not to pull Bolt the joint claws forcibly and remove the front cover downward HANDLEBAR FRONT REAR COVER ai ins REMOVAL ICE First remove the handlebar rear cover Remove the four screws attaching the handlebar rear cover Disconnect the wire connectors Remove the handlebar rear cover Remove the two screws attaching the handlebar front cover Remove the handlebar front cover Bolts The installation sequence 15 the reverse of removal FRONT RIGHT amp 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 covers The installation sequence is the reverse of removal When removing the right and left side rails pull them backward not to damage the joint claws
63. ing procedure Incorrectly adjust ed idle speed Air leaking through intake pipe QG Incorrect ignition Engine fires but Engine does not does not start fire timing Remove spark plug and inspect again Wait for 30 minutes and then remove the carbu retor auto choke Flooded carburetor Dry spark plug Wet spark plug Throttle valve excessively open circuit hose and blow the hose with mouth Not clogged Clogged Faulty auto bystarter 2 16 KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 ENGINE STOPS IMMEDIATELY AFTER IT STARTS Inspection Adjustment Probable Cause Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged float valve Clogged fuel filter Faulty auto fuel valve OONO Fuel reaches Fuel does not carburetor reach carburetor Remove D plug and install it into spark pu cap to test spark by connecting it to engine ground Plug not fouled or Plug fouled or 1 Fouled spark plug discolored discolored Q Incorrect heat range plug Remove spark plug and it into spark plug cap to test spark connecting it D Fouled spark plug to engine ground Q Faulty CDI unit Weak or inter 9 Faulty A C generator Good spark Faulty ignition Broken shorted high tension wire Test cylinder Faulty ignition switch compression using compression gauge Worn cylinder and piston rings D Normal Abnor
64. ing 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 oil seal KYMCO 9 FINAL REDUCTION ZX I SCOUT 50 Bolts FINAL REDUCTION DISAS SEMBLY Remove the rear wheel 14 3 Remove the left crankcase cover 8 3 Remove clutch driven pulley 8 7 Drain 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 Driver shift Remove the final gear and countershaft Countershaft Final Gear Dowel Pin FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage Countershaft KO KYMCO 9 FINALREDUCTION ZX SCOUT 50 Inspect the final gear and final shaft for wear damage or seizure Check the left crankcase bearings for Final Shaft excessive play and inspect the oil seal for wear or damage Drive Shaft Bearing Oil Seal Inspect the drive shaft and gear for wear or damage Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage Do n
65. irst 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 removing the brake fluid pipe bolt be sure to plug the pipe to avoid brake fluid leakage Disassembly Remove the piston rubber cover and snap ring from the brake master cylinder Master Cylinder Spring Main Piston Remove the washer main piston and spring from the brake master cylinder Clean the inside of the master cylinder and brake reservoir with brake fluid d Washer Snap Ring 13 11 13 STEERINGHANDLEBARFRONTWHEELFRONT dC KYMCO BRAKEFRONTSHOCK ABSORBER FRONT FORK AUNT Inspection Measure the brake master cylinder I D Service Limit 12 75mm Inspect the master cylinder for scratch or crack Measure the brake master cylinder piston O D Service Limit 12 6mm Before assembly inspect the Ist and 2nd rubber cups for wear Assembly Before assembly apply brake fluid to all removed parts Install the spring together with the 1st rubber cup During assembly the main piston and spring must be installed as unit without exchange When assembling piston soak cups in brake fluid for a while Install the cups with the cup lips facing the correct direction Install the main piston spring and snap ring Install the rubber
66. le of the exhaust muffler to reduce pollutants in the exhaust emission Exhaust Muffler Diagram Catalytic Converter FUNCTION E LM E xu a TA Jo arr dr gr i m IT Ee Lt Wy om I2 i 7 Jes y m Th E n LUPUS S SS n ME BW FEN gt tcs 4 5 amp 1 z E 1 i pi i gut x T Fi E m gt j adl Pi P s Az h e i Er iw ET oo Oxidizing HC and CO in the exhaust emission Catalytic Converter TROUBLESHOOTING Lack of power and high CO amp HO 1 Clogged exhaust muffler 2 Faulty oxidizing catalytic converter 3 Carburetor adjusted improperly 4 Clogged air cleaner 5 Faulty spark plug 6 Incorrect ignition timing 17 1 Reduce the concentration of The precious metal in the oxidizing catalytic converter 1s used to oxidize HC and CO in the exhaust emission into CO2 and H20 to avoid air pollution Engine runs erratic at idle speed and high fuel consumption 1 Clogged exhaust muffler 2 Clogged carburetor 3 Clogged air cleaner 4 Faulty spark plug 5 Incorrect ignition timing 17 EVAPORATIVE EXHAUST EMISSION Co KYMCO CONTROL SYSTEM EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts and two exhaust muffler lock bolts Remove the exhaust muffler The temperature of
67. lean 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 4 6 KYMCO 5 ENGINE REMOVAL INSTALLATION ZX SCOUT 50 ENGINE REMOVAL INSTALLATION SERGE IN ORT Ne 5 1 ENN REMOVA P 5 2 ENGINE INSTALLATION 5 4 5 0 KYMCO 5 ENGINE REMOVAL INSTALLATION ZX I SCOUT 50 SERVICE INFORMATION GENERAL INSTRUCTIONS Parts requiring engine removal for servicing Crankcase Crankshaft TORQUE VALUES Engine mounting bolt 45 5 5kg m Rear shock absorber lower mount bolt 2 4 3 0kg m Engine hanger bracket bolt 3 5 4 5kg m 5 1 KYMCO 5 ENGINE REMOVAL INSTALLATION ZX I SCOUT 50 Band Air Cleaner Case ENGINE REMOVAL Remove the frame body cover 12 5 Remove the two bolts attaching the air cleaner case Loosen the band between the air cleaner and carburetor to remove the air cleaner case Remove the carburetor cap Generator Wire Disconnect the oil pump control cable from TP IDE Line _ Connector the pump body Disconnect the oil inlet line from the oil pump After the oil inlet line is disconnected plug the oil line opening to prevent oil from flowing out Disconnect the auto bystarter A C generator and starter motor wire connectors
68. luid line Deformed brake disk Unevenly worn brake caliper Front wheel wobbling Bent rim Loose front axle Bent spoke plate Faulty tire Improperly tightened axle nut Soft front shock absorber Weak shock springs Insufficient damper oil Front shock absorber noise Slider bending Loose fork fasteners Lack of lubrication 13 2 KYMCO STEERINGHANDLEBARFRONTWHEEL FRONT 7X I SCOUT 50 BRAKEFRONTSHOCK ABSORBER FRONT FORK STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers 12 3 Remove two bolts attaching the left brake lever holder Remove two bolts attaching the brake master cylinder disk brake to the right brake lever Brake Master Cylinder Bolts Bolts Remove the two right handlebar switch Bolts Throttle Cable housing bolts and separate the housing Disconnect the throttle cable and then remove the throttle pipe from the handlebar Throttle Pipe Remove the handlebar lock nut to remove Handlebar the handlebar 13 3 KYMCO STEERINGHANDLEBARFRONTWHEEL FRONT 7X I SCOUT 50 BRAKEFRONTSHOCK ABSORBER FRONT FORK Tab Groove INSTALLATION Install the handlebar aligning the tabs of the handlebar with the grooves in the steering stem Install and tighten the handlebar lock nut Torque 4 5 5 0kg m Throttle Cable Lubricate the throttle pipe front end with grease Install the throttle grip and connect the throttle
69. mal Q Blown cylinder head compression compression gasket Flaws in cylinder head 4 Faulty reed valve Seized piston Check carburetor for clogging Not Clogged Clogged Clogged carburetor jets Check ignition timing D Faulty CDI unit or A C 2 A C G flywheel not aligned Check carburetor air screw adjustment 9 Mixture too rich turn Correctly adjusted Incorrectly adjusted screw out Mixture too lean turn screw in 2 17 KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 Inspection Adjustment Check carburetor gasket for air leaks Probable Cause D Carburetor not securely tightened gasket Deformed or broken carburetor O ring Remove auto bystarter connecting wire and check if bypass fuel line is clogged D Broken cable Not clogged Clogged Dirty auto bystarter Faulty auto bystarter Connect auto bystarter wire to battery Wait for 5 minutes then connect hose to fuel enriching circuit and then blow the hose with mouth Faulty auto bystarter Clogged Not Clogged N 2 18 KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 ENGINE LACKS POWER Inspection Adjustment Start engine and accelerate lightly for observation Probable Cause D Clogged air cleaner 2 Clogged fuel filter Clogged exhaust muffler Faulty auto bystarter Engine speed does not increase sufficiently Engine speed inc
70. move the flywheel nut Universal Holder KYMCO ZX I SCOUT 50 Nut KO KYMCO 7 A C GENERATOR ZX I SCOUT 50 Remove the A C generator flywheel using the flywheel puller Flywheel Puller A C Generator Wi Remove the A C generator wire connector AI EN Remove two pulser coil bolts and pulser coil from the right crankcase Remove the pulser coil wire clamp from the right crankcase Remove the two bolts attaching the A C generator stator Be careful not to damage the discon nected wire A C GENERATOR INSTALLATION Install the A C generator stator and pulser wire clamp onto the right crankcase and then install the pulser coil Pulser Coil 7 4 KO KYMCO 7 A C GENERATOR ZX SCOUT 50 Connect the A C generator wire connector Woodruff Ke Clean the taper hole in the flywheel off any burrs and dirt Install the woodruff key in the crankshaft keyway MEE VU 3 2 E 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 3 7 Install other removed parts in the reserve order of removal dd Universal Holder 8 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY ZX SCOUT 50 KICK STARTER DRIVE PUL
71. ms Install the set plate and then tighten the two SCrews Set Plate Screws FLOAT CHAMBER Remove the two float chamber screws and the float chamber Float Pin O ring Remove the screw and O ring Remove the float pin float and float valve Float 11 8 KYMCO 11 CARBURETOR ZX I SCOUT 50 Float Valve FLOAT FLOAT VALVE INSPECTION Inspect the float for damage or fuel inside the float r Check the float valve seat for wear or damage Float Seat Main Jet JETS SCREWS REMOVAL Before removing the throttle stop screw or air screw record the number of rotations until it seats lightly Then remove them Remove the main jet and needle jet holder Throttle Stop Screw Air Screw CARBURETOR PASS AGES CLEANING Blow compressed air through all passages of the carburetor body with an air gun 11 9 11 CARBURETOR FLOAT CHAMBER ASSEMBLY Install the main jet and needle jet holder Install the air screw and throttle stop screw according to the rotations recorded Install the float valve float and 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 specified level range Install the O ring Check the operation of the float and install the float chamber Tighten the screws KYMCO
72. nnect the emission tester sampling pipe to exhaust muffler Standard CO 340 5 HC 7000PPM max 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 I turns If the adjustment of carburetor makes no difference inspect exhaust emission related system 17 3
73. nnect the throttle cable from the throttle valve Naa 4 Rubber Seal Remove the throttle valve spring carburetor cap and rubber seal Carburetor Cap 11 3 dC KYMCO 11 CARBURETOR ZX SCOUT 50 Remove the jet needle by removing the needle clip Check the jet needle and throttle valve for dte Clip wear or damage Retainer Jet Needle 2 Notch STD Throttle Valve Rubber Seal Carburetor Cap THROTTLE VALVE INSTALLA Kt TION Install 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 Throttle Cable 11 4 KYMCO 11 CARBURETOR ZX I SCOUT 50 Groove Install the throttle valve by aligning the groove in the throttle valve with the throttle stop screw Throttle Stop Screw Carburetor Cap Tighten the carburetor cap After installation perform the following adjustments and inspections Throttle cable free play 3 11 Idle speed adjustment 3 8 Install the met in box CARBURETOR REMOVAL Remove 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 drain bolt to drain fuel from the carburetor Disconnect the auto bystarter wire connector Remove the two carburetor lock n
74. ombustion Chamber COMBUSTION CHAMBER DECABONIZING Remove the carbon deposits from the combustion chamber Avoid damaging the combustion cham ber wall and cylinder mating surface Mating Surface CYLINDER HEAD INSPECTION Check the cylinder head for warpage with straight edge and feeler gauge Service Limit 0 10mm replace if over CYLINDER HEAD INSTALLATION Install the cylinder head on the cylinder Cylinder head Gasket properly Be careful not to damage the mating surfaces Install new cylinder head gasket onto the cylinder KYMCO 6 CYLINDER HEAD CYLINDER PISTON ZX SCOUT 50 Cylinder head Bolts Cylinder Head Bolts Installation Install and tighten the cylinder head bolts diagonally in 2 or 3 times Torque 1 5_ 1 7kg m Install the spark plug Torque 1 1_ 1 7kg m Cylinder Head Spark Plug 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 6 5 KYMCO 6 CYLINDER HEAD CYLINDER PISTON ZX SCOUT 50 Joint Lock Nuts Cylinder CYLINDER PISTON CYLINDER REMOVAL Remove the met in box and seat Remove the frame body cover Remove the cylinder head Remove the two exhaust muffler joint lock nuts and two exhaust muffler lock bolts Remove the exhaust muffler Remove the cylinder Remove the cylinder gask
75. on switch Between ignition coil and spark plug Faulty ignition switch Faulty ignition coil Faulty CDI unit Faulty A C generator STARTING SYSTEM Starter motor won t turn Fuse burned out Weak battery Faulty ignition switch Faulty starter switch Faulty front or rear stop switch Faulty starter relay Poorly connected broken or shorted wire Faulty starter motor KYMCO ZX SCOUT 50 Engine starts but turns poorly Ignition primary circuit Faulty ignition coil Poorly connected wire or connector Ignition secondary circuit Faulty ignition coil Faulty spark plug Poorly insulated plug cap Improper ignition timing Battery voltage too low 6V max Faulty CDI unit Lack of power Weak battery Loose wire or connection Foreign matter stuck in starter motor or pinion Starter motor rotates but engine does not start Faulty starter pinion Starter motor rotates reversely Faulty starter clutch Weak battery 15 2 4O KYMCO 15 ELECTRICAL EQUIPMENT ZX I SCOUT 50 CHARGING SYSTEM 15 3 Dimmer Switch Headlight Switch Ignition Switch Battery A C Generator Regulator Rectifier Battery 2V3AH AC Hy starter Generator 18152 KYMCO 15 ELECTRICAL EQUIPMENT ZX I SCOUT 50 Battery Cover F 2 E BATTER
76. ont brake lining thickness 3 8 Brake disk runout o S i S ao 2 0 0 0 0 gt KYMCO ZX I SCOUT 50 ront shock absorber spring free length 35 rake master cvlinder piston O D 12 657 12 684 12 64 rake caliper piston O D 25 400 25 405 25 45 rake caliper piston I D TORQUE VALUES Handlebar lock nut 4 0 5 0kg m Steering stem lock nut 8 0 12 0kg m Steering top cone race 0 5 1 3kg m SPECIAL TOOLS Lock nut wrench Lock nut socket wrench Outer driver 28x30mm Rear shock absorber remover Rear shock absorber compressor Ball race remover TROUBLESHOOTING Hard steering heavy Excessively tightened steering stem top cone race Broken steering balls Insufficient tire pressure Steers to one side or does not track straight Broken clutch weight spring Bent front fork Bent front axle or uneven tire Poor brake performance Incorrectly adjusted brake Worn brake linings Contaminated brake lining surface Worn brake cam Worn brake drum Poorly connected brake arm Poor brake performance disk brake ir in brake system Deteriorated brake fluid 25 318 25 368 25 30 Front damper nut 1 5 Front axle nut 5 0 7 0kg m Brake arm bolt 0 4 Driver handle Outer driver 37x40mm Pilot 10mm Bearing puller Snap ring pliers close Damper compressor Contaminated brake disk or disk pad Worn brake bushing Worn brake master cylinder piston oil seal Clogged brake f
77. ool 10 6 KYMCO 10 CRANKCASE CRANKSHAFT ZX I SCOUT 50 CRANKCASE ASSEMBLY Dowel Pins Install the dowel pins and new gasket to the crankcase mating surface Assemble the crankcase halves Crankcase Assembly Tool The distance between the right crankcase oil seal and crankcase surface is about 12 5 0 5 mm Crankcase Assembly Tool 10 7 dC KYMCO 10 CRANKCASE CRANKSHAFT ZX I SCOUT 50 Oil Seal The distance between the left crankcase oil seal and crankcase surface is about 1 0mm Install and tighten crankcase attaching ni bolts 10 8 KYMCO 11 CARBURETOR ZX SCOUT 50 CARBURETOR 11 2 5 11 2 THROTTLE VALVE 5 11 3 THROTTLE VALVE 11 4 CARBURETOR 11 5 00 11 6 FLOAT 11 8 FLOAT LEVEL INSPECTION es 11 10 CARBURETOR INSTALLATION nmm 11 11 AIR SCREW 11 11 REED 11 12 FUEL 11 13 KYMCO 11 CARBURETOR ZX I SCOUT 50 KYMCO 11 CARBURETOR ZX SCOUT 50 SERVICE INFORMATION GENERAL
78. ot clogged D Faulty auto bystarter 2 21 KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 CLUTCH DRIVE AND DRIVEN PULLEYS Engine starts but motor cycle does not move Motorcycle creeps or engine starts but soon stops or seems to rush out Rear wheel rotates when engine idles Engine lacks power at start of a grade poor slope performance Engine lacks power at high speed There is abnormal noise or smell while running Symptom Steering is heavy Front or rear wheel is wobbling Steering handlebar pulls to one side NO Probable Cause Worn or slipping drive belt Broken ramp plate Broken driven face spring Separated clutch lining Damaged driven pulley shaft splines Damaged final gear Seized final gear L AINT Broken shoe spring Clutch outer and clutch weight stuck Seized pivot O Worn or slipping drive belt 2 Worn weight rollers 3 Seized drive pulley bearings 2 Weak driven face spring Worn or seized driven pulley bearings Worn or slipping drive belt Worn weight rollers Worn or seized driven pulley bearings ONO Oil or grease fouled drive belt Worn drive belt Weak driven face spring Worn or seized driven pulley bearings STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Probable Cause Front and rear tire pressures are normal D Steering stem nut too tight 2 Broken steering steel balls D Excessive wheel bearing play
79. ot remove the transmission case cover except for necessary part replace ment When replacing the drive shaft also replace the bearing and seal 9 4 KYMCO 9 FINAL REDUCTION ZX I SCOUT 50 Drive Shaft Bearing BEARING REPLACEMENT Transmission Case Cover Remove the transmission case cover bearings using the bearing remover Remove the final shaft oil seal Bearing Remover Set Bearing Outer Driver Handle A Drive new bearings into the transmission CASC COVCT BEARING REPLACEMENT Crankcase Cover Remove the drive shatt Remove the drive shaft oil seal Remove the left crankcase bearings using the bearing remover Bearing Remover Set 12mm 9 5 dC KYMCO 9 FINAL REDUCTION ZX I SCOUT 50 Drive new bearings into the left crankcase Install a new drive shaft oil seal FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Drive Shaft Install the final gear and final shaft into the left crankcase 9 6 9 FINAL REDUCTION Install the countershaft and gear into the left crankcase Install the resin washer onto the counter shaft Install the dowel pins and new gasket 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 9 7 KYMCO ZX SCOUT 50 Dowel Pins Countershaft R
80. ove with brake fluid Be careful not to damage the piston surface 13 14 SIEFRINGHANDI FBARFRONTWHETI FRONT ark BRAKEFRONTSHOCK ABSORBER FRONT FORK Check the piston for scratch or wear Measure the piston O D with a micrometer Service Limit 25 30mm Check the caliper cylinder for scratch or wear and measure the cylinder bore Service Limit 25 45mm Assembly Clean all removed parts Apply silicon grease to the piston and oil seal Lubricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved side facing out Install the piston with its outer end 3_ 5mm protruding beyond the brake caliper Wipe off excessive brake fluid with clean shop towel Apply silicon grease to the brake caliper seat pin and caliper inside Install the brake caliper seat 13 15 KYMCO SIEFRINGHANDI FBARFRONTWHETI FRONT 7X SCOUT 50 BRAKEEFRONTSHOCK ABSORBER FRONT FORK Installation Install the brake caliper and tighten the two bolts Torque 2 9 3 5kg m Connect the brake fluid pipe to the brake caliper and tighten the fluid pipe bolt Torque 3 0 4 0kg m Fill the brake reservoir with recommended brake fluid and bleed air from the brake system 13 9 13 16 13 STEERINGHANDLEBARFRONTWHEELFRONT ape BRAKEFRONTSHOCK ABSORBERFRONTFORK FRONT SHOCK ABSORBER REMOVAL Remove front wheel 13 5 Remove
81. ply locking agent to the washer and socket hex bolt and install them together Torque 1 5 3 0kg m Specified Oil ss 8 Oil Capacity 61cc Bolt Washer Install the circlip D Install the dust boot Dust Boot 13 19 BRAKFEFRONTSHOCK ABSORBER FRONT FORK INSTALLATION Mount POE Install the front shock absorbers onto the steering stem Install and tighten the front shock absorber upper mount bolts Tighten the lower mount bolts Install the front wheel 13 8 Front Shock Absorber FRONT FORK REMOVAL Remove the steering handlebar 13 3 Disconnect the speedometer cable and front brake fluid pipe and remove the front brake caliper Remove the front wheel 13 5 Hold the steering stem top cone race and remove the steering stem lock nut i i i LG Remove the top cone race and remove the front fork Be careful not to lose the steel balls 26 on top race and 29 on bottom race Inspect the ball races cone races and steel balls for wear or damage Replace if necessary Top Cone Race 13 20 13 STEERINGHANDLEBARFRONTWHEELFRONT ape BRAKEFRONTSHOCK ABSORBERFRONTFORK BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race using a chisel Drive a new bottom cone race into place with a proper driver Be careful not to damage the steering stem and front fork Bottom Cone Race BALL RACE REPLACEMENT Ball Race Remover Drive out the ball
82. reases E D Faulty CDI unit Correct timing Incorrect timing Faulty A C generator Test cylinder compression using a compression gauge Worn cylinder and OD Normal Abnormal piston rings _ compression compression 2 E Blown cylinder head gasket 3 Faulty reed valve Check carburetor for clogging Not Clogged Clogged DV Clogged carburetor jets Remove spark plug Plug not fouled or Plug fouled or Fouled spark plug discolored discolored Incorrect heat range plug Check if engine overheats OD Mixture too lean 2 Poor quality fuel Excessive carbon build overheats up in combustion chamber Ignition timing too early accelerate or run at high speed OD Excessive carbon build up in combustion chamber oo Engine knocks Q Poor quality fuel E Clutch slipping Mixture too lean 2 19 KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Probable Cause Check ignition timing D Faulty CDI unit Correct timing Incorrect timing Q Faulty A C generator Check carburetor air screw adjustment N ji D Mixture too rich turn Correctly adjusted Incorrectly adjusted screw out Mixture too lean turn screw in Check carburetor gasket for air leaks ii not securely No air leak tightene 00068 Q Faulty intake manifold Remove DE plug gasket and install it into 8 Deformed
83. rive in the right bearing Drive the bearing squarely with the sealed end facing out Outer Driver 28x30mm 13 7 KYMCO SIEFRINGHANDI FBARFRONTWHETI FRONT 7X SCOUT 50 BRAKE FRONTSHOCK ABSORBER ERONTFORK Side Collar Apply grease to the dust seal lip and install the dust seal Install the side collar Axle Nut Groove Tab 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 13 8 13 STEERINGHANDLEBARFRONT WHEELFRONT KYMCO ___ BRAKEFRONTSHOCKABSORBERFRONTFORK SCOUT 50 HYDRAULIC BRAKE FRONT BRAKE Upper Limit 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 coated surfaces to avoid damage caused by spill of brake fluid Lower Limit Brake Fluid Bleeding Bleed Valve In order to avoid spill of brake fluid connect a transparent hose to the 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 Fully apply the brake lever and then loosen the brake caliper bleed valve to drain the brake fluid until there is no
84. s the reverse of removal Screws 16 7 dC KYMCO 16 INSTRUMENT SWITCHES LIGHTS ZX I SCOUT 50 INSTRUMENT Instrument Bulbs Replacement Remove handlebar rear cover gt 12 3 Remove the bulbs and replace with new ones Bulb Sockets Speedometer cable SPEEDOMETER REMOVAL Disconnect the speedometer cable Disconnect the speedometer wire connector Remove the three screws attaching the speedometer Remove the speedometer The installation sequence 1s the reverse of removal Bulb Sockets HEADLIGHT REMOVAL BULB REPLACEMENT Remove handlebar front cover gt 12 3 Remove the bulb sockets and bulbs The model adopts krypton gas bulb When installing do not directly touch the bulb glass with fingers Use bulbs of the same specifications fo replacement The installation sequence is the reverse of removal 16 8 17 EVAPORATIVE EXHAUST EMISSION C KYMCO CONTROL SYSTEM ZX SCOUT 50 EVAPORATIVE EXHAUST EMISSION CONTROL SYSTEM EXHAUST EMISSION CONTROL SYSTEM 17 1 EXHAUST MUFFLER 1 5 20 01 0 0 0 0 0000 17 2 EXHAUST EMISSION RELATED SYSTEM INSPECTION 17 3 17 0 17 EVAPORATIVE EXHAUST EMISSION CONTROL SYSTEM KYMCO ZX I SCOUT 50 EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system adopted by this model is an oxidizing catalytic converter which is located in the midd
85. shing and return spring onto the left crankcase cover If the hooks of the return spring can not be installed properly use screw driver to press them into their locations respectively Properly install the kick starter driven gear and friction spring as the figure shown 8 5 ZX SCOUT 50 Kick Starter Spindle Forcing Part Kick Starter Driven Gear Forcing Part Kick Starter Spindle Return Spring Friction Spring Kick Starter Driven Gear 8 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY ZX SCOUT 50 First install the washer and then the circlip onto the kick starter spindle Install the kick lever Washer Circlip Dowel Pins LEFT CRANKCASE COVER INSTALLATION First install the dowel pins and then the seal rubber Left Crankcase Cover Install the left crankcase cover and tighten the nine bolts diagonally Connect the drive belt cooling air tube and install the circlip For drum brake note the location of the brake cable clamp and install the rear brake cable in place with the clamp 8 KICK STARTER DRIVE PULLEY O KYMCO CLUTCH DRIVEN PULLEY ZX SCOUT 50 DRIVE BELT Remove the left crankcase cover INSPECTION Check the drive belt for cracks separation or abnormal or excessive wear Measure the drive belt width Service Limit 16 5mm replace if below Use specified genuine parts for replace ment REPLACEMENT Remove the nine left crank
86. ssion e C D e lt 5 Dry multi disc clutch Transmission gear operation type Transmission ratio 1 speed Ist reduction ratio 2nd reduction Automatic centrifugal type Two stage reduction ratio Non stage transmission Tire pressure Front kg em Front Shock absorber Front Telescope ope Exhaust CO 4 5 emission concentration Brake svstem type Suspension type KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 Mg GENERAL INFORMATION ENGINE SERIAL jd SERVICE PRECAUTIONS 2502 SERVICE 0 tene 2 6 TORQUE 6 000 2 8 SPECIAL 86 99 2 9 LUBRICATION 8 00 0 6 2 11 WIRING DIAGRAM nnnc 2 15 CABLE amp HARNESS ROUTING eee 2213 TROUBLESHOOTING eene enne n 2 17 2 0 KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 ENGINE SERIAL NUMBER IDENTIFICATION Location of Engine Serial Number 2 1 KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 SERVICE PRECAUTIONS E Apply or add designated greases and lubricants to the specified lubrication oints Make sure to install new gaskets O rings P circlips cotter pins
87. t 10mm bolt nut 0 8mm flange bolt nut 12mm bolt nut 0 10mm flange bolt nut KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 SPECIAL TOOLS E020 Drive shaft bearing removal installation Tool Name niversal bearing puller Lock nut socket wrench Lock nut wrench Crankcase puller Bearing remover set 12mm Spindle assy 12mm Remover weight Bearing remover set 15mm Drive shaft bearing removal installation E018 Spindle assy 15mm Remover head 15mm Remover shaft 15mm Bearing outer driver 28x30mm E014 Bearing installation E027 Driven pulley disassembly assembly Driven shaft crankshaft amp crankcase E023 assembly E024 Crankshaft amp crankcase assembly 005 Steering stem bearing races 004 Rear shock absorber disassembly assembly E017 Flywheel holding E001 Flywheel removal E014 Drive shaft bearing installation Final shaft bearing installation Clutch spring compressor Crankcase assembly collar Crankcase assembly tool Ball race remover Rear shock absorber compressor niversal holder RE lt 3 E G Bearing outer driver 32x35mm Drive shaft bearing installation Final shaft 99 I gt lt P 5 014 bearing installation Crankshaft bearing installation E030 Crankshaft bearing removal 00 OG zi lt G 2 niversal bearing puller I 2 2 GENERAL INFORMATION SCOUT 50 LUBRICATION POINTS
88. tch ON Inspection Adjustment Probable Cause Check battery circuit by operating turn signals Burned out fuse Weak or dead battery Faulty ignition switch Loose or disconnected connector Signals operate Signals dim remain properly Broken wire harness Bulb lights Bulb does not light Burned out bulb eo oO Connect indicator light bulb to battery for bulb inspection Check connectors for proper operation D Loose wire connector Faulty 2 Broken wire harness Incorrectly connected Remove oil meter and wire check operation of indicator light by moving float D Faulty float Q Broken or shorted wire Float up Light off Float down Light on he 2 Motor oil 15 sufficient but the indicator light remains on Ignition switch ON Inspection Adjustment Symptom Probable Cause Check connectors for proper connection Loose or disconnected connector Q Broken wire harness 0 Incorrectly connected wire Remove oil meter and check operation of indicator light by moving float Faulty float Broken shorted wire in meter Float up Light off Float down Light on Damaged oil tank _ Foreign matters in oil tank 2 24 KYMCO 2 GENERAL INFORMATION ZX SCOUT 50 FUEL GAUGE 1 Pointer does not register correctly Ignition switch ON Inspection Adjustment Probable Cause Check battery circuit by operating turn signals D Burned out fuse We
89. ted wire in fuel gauge 2 25 2 GENERAL INFORMATION STARTER MOTOR 1 Starter motor won t turn Inspection Adjustment Check operation of stop switch b applying brake Stoplight comes Signals operate properly Relay operates properly Check battery circuit by operating turn signals Check operation of starter relay by depressing starter button Connect starter motor directly to battery Starter motor 2 Starter motor turns slowly or idles Inspection Adjustment Check battery Signals operate properly circuit by operating turn signals Starter motor turns slowly Connect starter motor directly to battery Rotate crankshaft 3 Starter motor does not stop turning Inspection Adjustment Turn ignition switch OFF Not stopped Symptom KYMCO ZX SCOUT 50 Probable Cause Burned out fuse Weak or dead battery Faulty stop switch Loose or disconnected connector Broken or shorted ignition switch wire Stoplight does not come on Signals dim remain on or don t Faulty or weak battery operate 2 Poor starter button connection Faulty starter relay Loose or disconnected connector Relay does not operate Starter does not Faulty starter motor Faulty wire harness Probable Cause Signals dim remain on or don t Weak or dead battery operate Loose or disconnected
90. the action of the front shock absorber by compressing it several times Check the entire shock absorber assembly for looseness or damage Check the action of the rear shock absorber by compressing it several times Check 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 Place the motorcycle on its main stand on level ground The gear oil level shall be at the oil check bolt hole Ifthe oil level is low add the specified oil to the proper level Specified Gear Oil SAE10W90 Install and tighten the oil check bolt Torque 1 0 1 5kg m Start the engine and check for oil leaks Oil Check Bolt 3 LUBRICATION SYSTEM ELECTRICAL EQUIPMENT IGNITION APPARATUS Spark Plug Gap Wear and Fouling Deposits Remove the frame center cover Remove the spark plug cap and spark plug Check the spark plug for wear fouling and carbon deposits Remove the fouling and carbon deposits with a spark plug cleaner or wire brush Specified Spark Plug Cracks BR8HSA Spark Plug Gap 0 0 0 7mm Ignition Apparatus The CDI ignition timing is not adjust able If the timing is incorrect check the CDI unit ignition coil and A C generator and replace any faulty parts Remove the right side rail 12 4 Remove the A C generator fan cover
91. tle cable Oil pump control cable 3 10 Rear brake cable 3 4 Oil pump bleeding 4 5 KYMCO 6 CYLINDER HEAD CYLINDER PISTON ZX I SCOUT 50 CYLINDER HEAD CYLINDER PISTON SERVICE JINECORIVERT Need 6 2 TROUBEE HOO TING ve 6 2 CYLINDER HEAD 6 3 CTHISDERPPES TON 6 6 6 0 KO KYMCO ZX SCOUT 50 6 CYLINDER HEAD CYLINDER PISTON _ 1 7kg m Torque 1 5 _ 1 7kg m Torque 1 1 cold 6 1 dC KYMCO 6 CYLINDER HEAD CYLINDER PISTON ZX SCOUT 50 SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder head cylinder and piston can be serviced with the engine installed in the frame Before disassembly clean the engine to prevent dust from entering the engine Remove all gasket material from the mating surfaces Do not use a driver to pry between the cylinder and cylinder head cylinder and crankcase Do not damage the cylinder inside and the piston surface After disassembly clean the removed parts before inspection When assembling apply the specified engine oil to movable parts SEECIEICATIONS Cylinder head warpage 040 Cylinder to piston clearance p 040 gt TORQUE VALUES Cylinder head bolt 1 5_ 1 7kg m Exhaust muffler joint lock nut 1 0 1 4kg m Exhaust muffler lock bolt 30 3 6kg m Spark plug 1 1_ 1 7kg m TROUBLESHOOTING Compression too low hard starting or poor performance at low speed Abnorm
92. uts Drain Bolt 11 5 KYMCO 11 CARBURETOR ZX SCOUT 50 Remove the carburetor AUTO BYSTARTER AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals Resistance 5Q 10 minutes minimum after stopping the engine If the resistance exceeds 50 replace the auto bystarter with new one After the engine stops for 30 minutes connect hose to the fuel enriching circuit and blow the hose with mouth If air cannot be blown into the hose clogged the auto bystarter 15 faulty Replace it with a new one 11 6 KYMCO 11 CARBURETOR ZX I SCOUT 50 Connect the auto bystarter yellow wire to the battery positive terminal and green black wire to the battery negative terminal and wait 5 minutes Connect hose to the fuel enriching circuit and blow the hose with mouth If air can be blown into the hose the auto bystarter is faulty and replace it with a new one Auto Bystarter AUTO BYSTARTER REMOVAL Remove the auto bystarter cover Remove the two auto bystarter set plate screws to remove the auto bystarter Screws Set Plate O ring Check the auto bystarter valve and needle for wear or damage Check the O ring for wear or damage Bystarter Bystarter Valve Needle 11 7 dC KYMCO 11 CARBURETOR zx scourso AUTO BYSTARTER INSTALLATION NIR Auto Bystarter Install the auto bystarter into the carburetor body until it botto

zx / scout 50 - Absolutely Scooters & Supply

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zx / scout 50 - Absolutely Scooters &amp; Supply

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zx / scout 50 - Absolutely Scooters & Supply