Kymco ZX/Scout - 49ccScoot.Com

Transcription

ZX / SCOUT
PREFACE
This Service Manual describes the technical feature.s and servicing
procedures for the KYMCO ZX / SCOUT 50.
In this manual, many illustrations and drawings are used to help
servicemen have better understanding.
Section 2 contains the service precautions for all operations and
troubleshooting stated in this manual. Read them carefully before
starting any operation.
Section 3 describes the inspection/adjustment procedures, safety rules and
service information for each part, starting from periodic maintenance.
Sections 4 through 16 give instructions for disassembly, assembly and
inspection of lubrication system, engine, fuel system and electrical
equipment.
Section 17 is the maintenance and inspection directions for the evaporative/
exhaust emission control system. Most sections start with an assembly or
system illustration and troubleshooting for the section. The subsequent
pages give detailed procedures for the section.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
MARCH 2000
1. SPECIFICATIONS
ZX / SCOUT
1
1
TABLE OF CONTENTS
SPECIFICATIONS ......................................................................................... 1
GENERAL INFORMATION......................................................................... 2
INSPECTION/ADJUSTMENT...................................................................... 3
LUBRICATION SYSTEM ............................................................................. 4
ENGINE REMOVAL/INSTALLATION...................................................... 5
CYLINDER HEAD/CYLINDER/PISTON................................................... 6
A.C. GENERATOR......................................................................................... 7
KICK STARTER/DRIVE PULLEY/CLUTCH/DRIVEN PULLEY......... 8
FINAL REDUCTION ..................................................................................... 9
CRANKCASE/CRANKSHAFT.....................................................................10
CARBURETOR...............................................................................................11
FRAME COVERS...........................................................................................12
STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/
FRONT SHOCK ABSORBER/FRONT FORK ...........................................13
REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER .................14
ELECTRICAL EQUIPMENT .......................................................................15
INSTRUMENT/SWITCHES/LIGHTS .........................................................16
EVAPORATIVE/EXHAUST EMISSION CONTRAL SYSTEM .............17
1-0
1. SPECIFICATIONS
ZX 50
SPECIFICATIONS
Name & Model
Overall length (mm)
Overall width (mm)
Overall height (mm)
Wheel base (mm)
Engine type
Displacement (cc)
Net weight (kg)
SC10AS
1792
690
1053
1225
Air cooled 2-stroke
49.4 cc
92.5
Lubrication oil capacity (liter)
Air cleaner type & No.
Fuel capacity (liter)
Type
Carburetor Piston dia. (mm)
Venturi dia. (mm)
Ignition system type
Ignition timing F mark
Spark
Seating capacity
2 riders (110kg)
Gross weight(kg)
150
plug
Spark plug gap (mm)
Tires
Ground clearance (mm)
Braking distance (m)
(Initial speed Km/h)
Min. turning radius (mm)
Starting system
Fuel type
Cylinder arrangement
Combustion chamber type
Valve arrangement
Bore x stroke (mm)
Compression ratio
Compression pressure
(kg/cm² rpm)
Max. output (kw/rpm)
Max. torque (kg-m/rpm)
Open
Intake
Close
Port
Open
Exhaust
timing
Close
Open
Scavenge
Close
Idle speed (rpm)
Lubrication type
Oil pump type
Oil filter type
1-1
14
CDI electromagnetic
Ignition
15.5°±2°BTDC/2000rpm
NGK
BR8HSA
ND
¯
0.6 0.7
Battery capacity
Front wheel
Rear wheel
0.80
Wet, single
4.9
Plunger type
⎯
12V3AH
Power-transmission
gear-clutch
120/70-12
120/70-12
170
Power to transmission gear
Reduction ratio of power to
transmission
⎯
7m (30km/h)
Clutch type
Transmission gear operation
type
Dry multi-disc clutch
Automatic centrifugal
type
1940
Starting motor &
kick starter
Gasoline, 2-stroke
motor oil
Single cylinder, flat
Semi-sphere
Reed valve & piston
39 x 41.4
7.3 : 1
11.5kg/cm²
3.75/7000kw/rpm
4.5/6500 kg m/rpm
Automatic controlled
Automatic controlled
⎯
⎯
⎯
⎯
2100±100
Separate type
Plunger type
Full-flow filtration
Transmission ratio
1 speed
⎯
Reduction Type
Two-stage reduction
⎯
gear
1st reduction ratio
⎯
2nd reduction ratio
Transmission gear type
Non-stage transmission
Front wheel
1.50
1.75
Tire pressure
(kg/cm²)
Rear wheel
1.75
2.25
Turning angle
Right & left 45°
Brake system
type
Suspension
type
Shock absorber
type
Frame type
Exhaust
emission
concentration
Front wheel Expanding/hydraulic
Rear wheel
Expanding
Front wheel
Telescope
Rear wheel
Unit swing
Front wheel
Telescope
Rear wheel
Unit swing
Pipe under bone
CO
4.5%
HC
7000ppm Max
2. GENERAL INFORMATION
ZX / SCOUT
1
2
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
GENERAL INFORMATION
__________________________________________________________________________________
ENGINE SERIAL NUMBER/IDENTIFICATION............................. 2- 1
SERVICE PRECAUTIONS................................................................. 2- 2
SERVICE INFORMATION ................................................................ 2- 6
TORQUE VALUES ............................................................................. 2- 8
SPECIAL TOOLS ................................................................................ 2- 9
LUBRICATION POINTS .................................................................... 2-11
WIRING DIAGRAM ........................................................................... 2-12
CABLE & HARNESS ROUTING....................................................... 2-13
TROUBLESHOOTING ....................................................................... 2-17
2-0
ENGINE SERIAL NUMBER/IDENTIFICATION
Location of Engine Serial Number
2-1
ZX / SCOUT
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when reassembling.
When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
Use genuine parts and lubricants.
When servicing the motorcycle, be sure to
use special tools for removal and
installation.
After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.
ZX / SCOUT
Apply or add designated greases and
lubricants to the specified lubrication
points.
After reassembly, check all parts for proper
tightening and operation.
When two persons work together, pay
attention to the mutual working safety.
Disconnect the battery negative (-) terminal
before operation.
When using a spanner or other tools, make
sure not to damage the motorcycle surface.
After operation, check all connecting
points, fasteners, and lines for proper
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
If the fuse is burned out, find the cause and
repair it. Replace it with a new one
according to the specified capacity.
ZX / SCOUT
The connector shall be inserted
completely.
If the double connector has a lock, lock
it at the correct position.
Check if there is any loose wire.
Easy confirm
After operation, terminal caps shall be
installed securely.
Before connecting a terminal, check for
damaged terminal cover or loose
negative terminal.
Check the double connector cover for
proper coverage and installation.
When taking out the connector, the lock on
the connector shall be released before
operation.
Hold the connector body when connecting
or disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is bending,
protruding or loose.
2-3
Insert the terminal completely.
Check the terminal cover for proper
coverage.
Do not make the terminal cover opening
face up.
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.
After clamping, check each wire to make
sure it is secure.
Do not squeeze wires against the weld or
its clamp.
After clamping, check each harness to
make sure that it is not interfering with any
moving or sliding parts.
When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
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.
ZX / SCOUT
Route harnesses so they are neither
pulled tight nor have excessive slack.
Protect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner.
When rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
Do not break the sheath of wire.
If a wire or harness is with a broken sheath,
repair by wrapping it with protective tape
or replace it.
When installing other parts, do not press or
squeeze the wires.
2-4
After routing, check that the wire harnesses
are not twisted or kinked.
ZX / SCOUT
Symbols:
The following symbols represent the
servicing methods and cautions included in
this service manual.
Wire harnesses routed along with
handlebar should not be pulled tight, have
excessive slack or interfere with adjacent
or surrounding parts in all steering
positions.
: Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
Engine Oil
: Apply grease for lubrication.
Grease
When a testing device is used, make sure to
understand the operating methods
thoroughly and operate according to the
operating instructions.
: Use special tool.
Special
: Caution
: Warning
Be careful not to drop any parts.
When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Remove the rest
2-5
(Ö12-3)
: Refer to page 12-3.
ZX / SCOUT
SERVICE INFORMATION
ENGINE
Item
Cylinder head warpage
Piston O.D.(5mm from bottom of piston skirt)
Standard (mm)
Service Limit (mm)
SC10AS
⎯
SC10AS
38.955 38.970
38.90
0.10
Cylinder-to- piston clearance
Piston pin hole I.D.
0.10
12.002 12.008
12.03
11.994 12.0
11.98
←
←
0.10 0.25
0.40
17.005 17.017
17.03
39.0 39.025
39.05
18
17
Drive pulley collar O.D.
20.01 20.025
←
Movable drive face ID.
20.035 20.085
19.97
13.0
12.4
107 107.2
107.5
87.9
82.6
Driven face O.D.
←
←
Movable driven face I.D.
←
←
Connecting rod big end side clearance
←
←
Connecting rod big end radial clearance
←
←
Crankshaft runout A/B
⎯
←
Piston pin O.D.
Piston-to-piston pin clearance
Piston ring end gap (top/second)
Connecting rod small end I.D.
Cylinder bore
Drive belt width
Weight roller O.D.
Clutch outer I.D.
Driven face spring free length
CARBURETOR
Venturi dia.
Identification number
Float level
SC10AS
14mm
014A
5.0mm
Main jet
#80
Slow jet
#35
Air screw opening
1 ±¼
Idle speed
2100±100rpm
Throttle grip free play
2 6mm
Jet needle clip notch
1st notch
2-6
FRAME
Item
Axle shaft runout
Front wheel rim runout
ZX / SCOUT
Standard (mm)
Service Limit (mm)
SC10AS
SC10AS
⎯
0.2
200.0
182.8
Radial
Axial
Front shock absorber spring free length
Rear wheel rim runout
2.0
Brake drum I.D.
Front/rear
110
111
Brake lining thickness
Front/rear
4.0/4.0
2.0/2.0
Brake disk runout
Front/rear
⎯
0.30
235.7
218.7
Rear shock absorber spring free length
ELECTRICAL EQUIPMENT
SC10AS
Capacity
Voltage
Battery
Charging
current
Spark plug
Standard
0.4A/5H
Quick
4A/0.5H
(NGK)
Spark plug gap
Primary coil
Secondary coil
Ignition coil resistance (with plug cap)
Secondary coil
(without plug cap)
Pulser coil resistance (20 )
Ignition timing
2-7
12V3AH
13.0 13.2V
BR8HSA
0.6 0.7mm
0.153 0.187Ω
6.99 10.21KΩ
3.24 3.96KΩ
80 160Ω
15.5°±2°BTDC/2000rpm
ZX / SCOUT
TORQUE VALUES
ENGINE
Item
Thread dia. (mm)
Cylinder head bolt
BF7x115
Clutch drive plate nut
10
Clutch outer nut
NH10
Drive face nut
NH12
Oil check bolt
10
Engine mounting bolt
BF10x95
Engine hanger bracket bolt
BF10x50
Exhaust muffler joint lock nut
NC6mm
Exhaust muffler lock bolt
BF8x35
Spark plug
Torque (kg-m)
1.5 1.7
3.5 4.0
3.5 4.5
5.0 6.0
1.0 1.5
4.5 5.5
3.5 4.5
1.0 1.4
3.0 3.6
1.1 1.7
Remarks
(cold)
(cold)
FRAME
Item
Thread dia. (mm)
Torque (kg-m)
Remarks
Handlebar lock nut
10
4.5 5.0
Flange bolt/U-nut
Steering stem lock nut
25.4
8.0 12.0
Steering top cone race
25.4
0.5 1.3
Front axle nut
12
5.0 7.0
Flange U-nut
Rear axle nut
16
11.0 13.0
Flange U-nut
Rear brake arm bolt
Flange nut
Front shock absorber:
upper mount bolt
8
3.3
Flange bolt/U-nut
lower mount bolt
3.3
Cross head
hex bolt
1.5 3.0
Apply locking agent
Front damper nut
8
1.5 3.0
Front pivot arm bolt
Flange screw/U-nut
Rear shock absorber:
upper mount bolt
10
3.5 4.5
Flange nut
lower mount bolt
8
2.4 3.0
lower joint nut
8
1.5 2.5
Torque specifications listed above are for important fasteners. Others should be tightened to
standard torque values below.
STANDARD TORQUE VALUES
bolt
Item
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
Torque (kg-m)
0.45 0.6
0.8 1.2
1.8 2.5
3.0 4.0
5.0 6.0
SH bolt: 8mm
Item
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
Flange 6mm
Torque (kg-m)
0.35 0.5
0.7 1.1
1.0 1.4
2.4 3.0
3.5 4.5
2-8
ZX / SCOUT
SPECIAL TOOLS
Tool Name
Tool No.
Remarks
Universal bearing puller
E030
Crankshaft bearing removal
Lock nut socket wrench
F001
Top cone race holding
Lock nut wrench,
F002
Stem lock nut tightening
Crankcase puller
E026
Crankcase disassembly
Bearing remover set, 12mm
(Spindle assy, 12mm)
(Remover weight)
E020
Drive shaft bearing removal/installation
(Spindle assy, 15mm)
(Remover head, 15mm)
(Remover shaft, 15mm)
E018
Drive shaft bearing removal/installation
Bearing outer driver, 28x30mm
E014
Bearing installation
Clutch spring compressor
E027
Driven pulley disassembly/assembly
Crankcase assembly collar
E023
Driven shaft, crankshaft & crankcase
assembly
Crankcase assembly tool
E024
Crankshaft & crankcase assembly
Ball race remover
F005
Steering stem bearing races
Rear shock absorber compressor
F004
Rear shock absorber disassembly/assembly
Universal holder
E017
Flywheel holding
Flywheel puller
E001
Flywheel removal
E014
Drive shaft bearing installation
Final shaft bearing installation
E014
Drive shaft bearing installation Final
shaft bearing installation Crankshaft
bearing installation
E030
Crankshaft bearing removal
2-9
ZX / SCOUT
LUBRICATION POINTS
ENGINE
NO.
1
2
3
4
5
6
Lubrication Points
Crankcase sliding & movable
Cylinder movable parts
Transmission gear (final gear)
Kick starter spindle bushing
Drive pulley movable parts
Starter pinion movable parts
Lubricant
JASO-FC or API-TC
JASO-FC or API-TC
SAE-90#
Grease
Grease
Grease
Remarks
FRAME
Apply clean engine oil or grease to cables and movable parts not specified.
abnormal noise and rise the durability of the motorcycle.
Grease
Front/Rear Brake Lever
Engine Oil
This will avoid
Grease
Engine Oil
Throttle Cable
Grease
Speedometer Gear/
Brake Cam/Front
Shock Absorber
Lower Mount
Bushings/Pivot
Seat Lock
Grease
Rear Wheel Bearing
Grease
Brake Cam/
Anchor Pin
Grease
Main Stand Pivot
Engine Oil
Rear Brake Cable
2-10
SC10AS WIRING DIAGRAM
2-11
ZX / SCOUT
ZX / SCOUT
CABLE & HARNESS ROUTING
Rear Stop Switch Wire
Front Stop Switch Wire
Front Brake Reservoir
Throttle Cable
Speedometer Cable
Rear Brake Cable
Front Brake Fluid Tube
Ignition Switch
Horn
Regulator/Rectifier
Resistor
Speedometer Cable
2-12
ZX / SCOUT
Throttle Cable
Speedometer Cable
Wire Harness
Speedometer Cable
2-13
Rear Brake Cable
ZX / SCOUT
Fuel Unit
Ignition Coil
Oil Tube
CDI Unit
Oil Tank Cap
Wire Harness
Fuel Filter
Battery
Ignition Coil
Starter Relay
2-14
Fuel Tank Cap
ZX / SCOUT
Fuel Unit
Vacuum Tee
Oil Tube
Oil Pump
Ignition Coil
2-15
ZX / SCOUT
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Inspection/Adjustment
Probable Cause
Symptom
Check if fuel reaches
carburetor by loosening
drain screw.
Fuel reaches
carburetor
Fuel does not
reach carburetor
Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
ground.
Spark jumps
Weak or no spark
Test cylinder
compression.
c Empty fuel tank
d Clogged float valve
e Clogged fuel filter
f Faulty auto fuel valve
c Faulty spark plug
d Fouled spark plug
e Faulty CDI unit
f Faulty A.C. generator
g Broken or shorted ignition coil
h Broken or shorted exciter coil
iFaulty ignition switch
Normal
compression
Low or no
compression
c Burned or worn cylinder
piston
d Faulty reed valve
e Blown cylinder head gasket
f Leaking crankcase
g Faulty crankcase oil seal
Engine does not
fire
Engine fires but
does not start
c Incorrectly adjusted idle speed
d Air leaking through intake
pipe
e Incorrect ignition timing
Dry spark plug
Wet spark plug
c Flooded carburetor
d Throttle valve excessively
open
Not clogged
Clogged
Start engine by
follow-ing normal
starting procedure.
inspect again.
Wait for 30 minutes and
then remove the
carbu-retor auto choke
circuit hose and blow
the hose with mouth.
c Faulty auto bystarter
2-16
ZX / SCOUT
ENGINE STOPS IMMEDIATELY AFTER IT STARTS
Symptom
Probable Cause
Check if fuel reaches
carburetor by loosening
drain screw.
Fuel reaches
carburetor
Fuel does not
reach carburetor
c Empty fuel tank
d Clogged float valve
e Clogged fuel filter
f Faulty auto fuel valve
Plug fouled or
discolored
c Fouled spark plug
d Incorrect heat range plug
ground.
Plug not fouled or
discolored
ground.
Good spark
Weak or intermittent spark
Test cylinder
compression (using a
compression gauge).
Normal
compression
Abnormal
compression
c Fouled spark plug
d Faulty CDI unit
e Faulty A.C. generator
f Faulty ignition coil
g Broken or shorted high
tension wire
h Faulty ignition switch
c Worn cylinder and piston
rings
d Blown cylinder head gasket
e Flaws in cylinder head
f Faulty reed valve
g Seized piston
Check carburetor for
clogging.
c Clogged carburetor jets
Not Clogged
Clogged
Correct timing
Incorrect timing
c Faulty CDI unit or A.C.
generator
d A.C.G. flywheel not aligned
Correctly adjusted
Incorrectly adjusted
c Mixture too rich (turn screw
out)
d Mixture too lean (turn screw
in)
Check ignition timing.
Check carburetor air
screw adjustment.
2-17
ZX / SCOUT
Symptom
Probable Cause
Check carburetor gasket
for air leaks.
No air leak
Air leaks
c Carburetor not securely
tightened
d Faulty intake manifold gasket
e Deformed or broken
carburetor O-ring
Not clogged
Clogged
c Broken cable
d Dirty auto bystarter
e Faulty auto bystarter
Clogged
Not Clogged
Remove auto bystarter
connecting wire and
check if bypass fuel
line is clogged.
Connect auto bystarter
wire to battery. Wait for
5 minutes, then connect
a hose to fuel enriching
circuit and then blow
2-18
ZX / SCOUT
ENGINE LACKS POWER
Symptom
Probable Cause
Start engine and
accelerate lightly for
observation.
Engine speed
increases
Engine speed
does
not increase
ffi i tl
c Clogged air cleaner
d Clogged fuel filter
e Clogged exhaust muffler
f Faulty auto bystarter
Check ignition timing
(using a timing light).
Correct timing
Incorrect timing
c Faulty CDI unit
d Faulty A.C. generator
Test cylinder
compression (using a
compression gauge)
Normal
compression
Abnormal
compression
c Worn cylinder and piston
rings
d Blown cylinder head gasket
e Faulty reed valve
Check carburetor for
clogging
Not Clogged
Clogged
c Clogged carburetor jets
inspect
Plug not fouled or
discolored
Plug fouled or
discolored
c Fouled spark plug
d Incorrect heat range plug
Engine overheats
c Mixture too lean
d Poor quality fuel
e Excessive carbon build-up in
combustion chamber
f Ignition timing too early
Engine knocks
c Excessive carbon build-up in
combustion chamber
d Poor quality fuel
e Clutch slipping
f Mixture too lean
Check if engine
overheats
Engine does not
overheats
Rapidly accelerate or
run at high speed
Engine does not
knock
2-19
ZX / SCOUT
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Symptom
Probable Cause
Correct timing
Incorrect timing
Correctly adjusted
Incorrectly adjusted
c Faulty CDI unit
d Faulty A.C. generator
Check carburetor air
screw adjustment.
c Mixture too rich (turn screw
out)
d Mixture too lean (turn screw
in)
Check carburetor gasket
for air leaks.
Air leaks
c Carburetor not securely
tightened
d Faulty intake manifold gasket
e Deformed carburetor O-ring
Good spark
Weak or intermittent spark
c Faulty or fouled spark plug
d Faulty CDI unit
f Faulty ignition coil
g Broken or shorted high
tension wire
h Faulty ignition switch
Not clogged
Clogged
Clogged
Not clogged
No air leak
ground.
connecting wire and
line is clogged.
c Broken auto bystarter wire
d Faulty auto bystarter
2-20
ZX / SCOUT
POOR PERFORMANCE (AT HIGH SPEED)
Symptom
Probable Cause
c Faulty CDI unit
d Loose A.C.G. stator
Correct timing
Incorrect timing
Fuel flows freely
Fuel flow restricted
Not clogged
Clogged
c Clean and unclog
Not clogged
Clogged
c Broken auto bystarter wire
d Faulty auto bystarter
Clogged
Not clogged
Check auto fuel valve
for fuel supply.
c Empty fuel tank
d Clogged fuel tube or filter
e Clogged charcoal canister
Check carburetor jets
for clogging.
connecting wire and
line is clogged.
2-21
ZX / SCOUT
CLUTCH, DRIVE AND DRIVEN PULLEYS
Symptom
Probable Cause
Engine starts but
motor-cycle does not
c Worn or slipping drive belt
d Broken ramp plate
e Broken driven face spring
f Separated clutch lining
g Damaged driven pulley shaft splines
h Damaged final gear
i Seized final gear
Motorcycle creeps or
engine starts but soon
stops or seems to rush
out (Rear wheel rotates
when engine idles)
c Broken shoe spring
d Clutch outer and clutch weight stuck
eSeized pivot
Engine lacks power at
start of a grade (poor
slope performance)
d Worn weight rollers
e Seized drive pulley bearings
f Weak driven face spring
g Worn or seized driven pulley bearings
Engine lacks power at
high speed
d Worn weight rollers
e Worn or seized driven pulley bearings
There is abnormal noise
or smell while running
c Oil or grease fouled drive belt
d Worn drive belt
e Weak driven face spring
f Worn or seized driven pulley bearings
STEERING HANDLEBAR DOES NOT TRACK STRAIGHT
Symptom
Probable Cause
(Front and rear tire pressures are normal)
Steering is heavy
c Steering stem nut too tight
d Broken steering steel balls
Front or rear wheel is
wobbling
c Excessive wheel bearing play
d Bent rim
e Loose axle nut
Steering handlebar pulls
to one side
c Misaligned front and rear wheels
d Bent front fork
2-22
ZX / SCOUT
POOR SUSPENSION PERFORMANCE
Symptom
Probable Cause
(Front and rear tire pressures are normal)
Suspension is too soft
c Weak shock spring
d Excessive load
e Shock damper oil leaking
Suspension is too hard
c Bent fork tube or shock rod
d Fork slider and tube binding
Suspension is noisy
c Fork tube and spring binding
d Fork slider and tube binding
POOR BRAKE PERFORMANCE
Symptom
Probable Cause
(Adjust brake according to standards)
Index mark on brake
panel aligns with wear
indicator arrow
c Worn brake linings
d Worn brake cam contacting area on
brake shoes
e Worn brake cam
f Worn brake drum
Brake squeaks
c Worn brake linings
d Foreign matter on brake linings
e Rough brake drum contacting area
Brake performance is
poor
c Sluggish or elongated brake cables
d Brake shoes improperly contact
brake drum
e Water and mud in brake system
f Oil or grease on brake linings
Expanding
Brake
Hydraulic
Brake
2-23
c Faulty brake master cylinder
d Faulty brake caliper
e Oil or grease on brake disk
f Deformed brake disk
g Leaking brake fluid tube
ZX / SCOUT
OIL METER
1. Motor oil indicator light does not come on when there is no motor oil (Ignition switch ON)
Symptom
Probable Cause
Check battery circuit by
operating turn signals.
Signals operate
properly
Signals dim, remain
on or don‘t operate
c Burned out fuse
d Weak or dead battery
e Faulty ignition switch
f Loose or disconnected
connector
g Broken wire harness
Bulb lights
Bulb does not light
cBurned out bulb
Good
Faulty
c Loose wire connector
d Broken wire harness
e Incorrectly connected wire
Good
Faulty
c Faulty float
d Broken or shorted wire in
meter
Connect indicator light
bulb to battery for bulb
inspection.
Check connectors for
proper operation.
Remove oil meter and
check operation of
indicator light by
moving float
Float up = Light off
Float down = Light on
2. Motor oil is sufficient but the indicator light remains on (Ignition switch ON)
Probable Cause
Symptom
proper connection.
Good
Faulty
Good
Faulty
Remove oil meter and
check operation of
indicator light by
moving float
Float up = Light off
Float down = Light on
c Loose or disconnected
connector
d Broken wire harness
e Incorrectly connected wire
c Faulty float
d Broken or shorted wire in
meter
c Damaged oil tank
d Foreign matters in oil tank
2-24
ZX / SCOUT
FUEL GAUGE
1. Pointer does not register correctly (Ignition switch ON)
Probable Cause
Symptom
operating turn signals.
Remove fuel unit and
check operation of
pointer by moving float
up and down.
Check operation of
pointer by opening and
shorting fuel unit
terminal on wire
harness side.
Signals operate
properly
Signals dim, remain
Pointer does not
move
Pointer does not
move
c Burned out fuse
connector
Pointer moves
c Faulty float
Pointer moves
c Broken or shorted fuel unit
wire
proper connection.
Faulty
Good
connector
d Incorrectly connected
connector
c Broken or shorted wire in
fuel gauge
2. Pointer fluctuates or swings (Ignition switch ON)
Probable Cause
Symptom
operating turn signals
and horn.
Remove fuel unit and
check operation of
pointer by moving float
up and down.
Move float up and
down rapidly (1 round
/sec.) to check the
operation of pointer.
Signals operate
properly
Signals dim, remain
Pointer moves
Pointer does not
move
Pointer moves in
accordance with
float
Pointer does not
move in
accord-ance with
c Burned out fuse
connector
c Poor contact in fuel unit
c Insufficient damping oil in
fuel gauge
proper connection.
Good
2-25
Faulty
connector
c Broken or shorted wire in
fuel gauge
ZX / SCOUT
STARTER MOTOR
1. Starter motor won‘t turn
Symptom
Probable Cause
Check operation of
stop switch by
applying brake.
Stoplight does not
come on
c Burned out fuse
e Faulty stop switch
connector
g Broken or shorted ignition
switch wire
Signals operate
properly
Signals dim, remain
c Faulty or weak battery
Relay operates
properly
Relay does not
operate
Starter motor turns
Starter does not turn
Stoplight comes on
Check battery circuit
by operating turn
signals.
Check operation of
starter relay by
depressing starter
button.
Connect starter
motor directly to
battery.
c Poor starter button connection
d Faulty starter relay
e Loose or disconnected
connector
c Faulty starter motor
c Faulty wire harness
2. Starter motor turns slowly or idles
Symptom
Probable Cause
Check battery circuit
by operating turn
signals.
Signals operate
properly
Signals dim, remain
c Weak or dead battery
Starter motor
turns slowly
Starter motor
turns normally
connector
d Faulty starter relay
Turns easily
Hard to turn
Connect starter
motor directly to
battery.
Rotate crankshaft.
c Seized cylinder
c Broken or shorted starter
motor cable
d Faulty starter pinion
3. Starter motor does not stop turning
Symptom
Probable Cause
Turn ignition switch
OFF.
Not stopped
Stopped
c Faulty starter pinion
c Starter relay shorted or stuck
closed
2-26
3. INSPECTION/ADJUSTMENT
ZX /SCOUT 50
3
__________________________________________________________________________________
3
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
INSPECTION/ADJUSTMENT
__________________________________________________________________________________
INSPECTION AND MAINTENANCE SCHEDULE......................... 3- 1
BRAKE SYSTEM................................................................................ 3- 4
MOVING DEVICE .............................................................................. 3- 5
DAMPING DEVICE............................................................................ 3- 6
POWER DRIVE SYSTEM .................................................................. 3- 6
ELECTRICAL EQUIPMENT.............................................................. 3- 7
ENGINE ............................................................................................... 3- 8
OTHERS............................................................................................... 3- 11
3-0
ZX /SCOUT 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 & Maintenance Item
Check for looseness and
Steering vertical play
handlebar
Operating performance
1st Every 6 Every 12
Preride month months months
○
○
○
○
Right/left turning angle
Suspension
Front
fork
Damage
○
○
Check for front fork
pivot installation
○
○
Check front fork pivot
for looseness and
abnormal noise
Brake
Lever
Lever/
Cable
Brake
System
○
○
○
○
Free play:
10 20mm
○
Brake performance
○
Looseness, abnormal
noise and damage
○
Drum-to-lining
clearance
Brake
drum/
shoe
Check
steering
stem
Check
steering
stem
○
Front/rear brake lever
free play
Brake lever operation
Judgment Standards Remarks
○
○
○
Brake shoe and lining
wear
Indicator
type
Brake drum wear and
damage
○
Standard:
Front: 110 mm
Rear : 110 mm
Service Limits:
Front: 111 mm
Rear : 111 mm
Front
Moving
Device
3-1
Tire
Tire pressure
○
○
○
Rear
1
1.50
1.75
rider kg/cm² kg/cm²
Tire 120/70- 120/70-1
2
Size 12
Moving
Device
Motorcycle
Damping
Device
Frequency
Tire crack and damage
○
○
○
Tire groove and
abnormal wear
○
○
○
Imbedded objects,
gravel, etc.
○
○
○
Axle nut looseness
Check wheel rim, rim
edge and spoke plate for
damage
Frame
Spring
ZX /SCOUT 50
○
○
○
○
Check front wheel
bear-ing for excessive
play and abnormal noise
○
Check front wheel
bear-ing for excessive
play and abnormal noise
○
Groove Depth:
Front: 0.8mm
Rear : 0.8mm
Torque Values:
Front axle nut
Axle nut
5.0 7.0kg-m
torque
Rear axle nut
11.0 13.0kg-m
Rim runout at rim end:
Front: Axial
2.0mm
Radial
2.0mm
Rear: Axial
2.0mm
Radial
2.0mm
Shock
spring
free
length
Damage
Suspen-si Connecting parts
on arm
loose-ness and arm
damage
○
Oil leakage and damage
Shock
absorber Assembly parts
loose-ness abnormal
noise
○
○
○
○
Transmission case Oil leakage and oil level
○
○
Oil level:
Oil check bolt hole
at lower hole edge
Ignition
device
Spark plug condition
○
○
Plug gap: 0.6 0.7mm
Electrical
Equipment Battery
Terminal connection
Power
Drive
System
Clutch
Operation
○
Rear wheel
transmission case
○
3-2
Wires
Loose connection and
damage
○
Frequency
Performance and abnormal
noise
Body
ZX /SCOUT 50
○
○
○
○
Exhaust smoke
○
○
Air cleaner
○
○
Oil quality and quantity
○
○
○
○
Conditions at low and high
speeds
LubricaOil leakage
Engine tion
system
Oil level
○
Oil level indicator
Indicator light comes on
when oil is insufficient
○
○
Check oil filter for clogging
Fuel leakage
Carburetor, throttle valve and
auto bystarter
○
Fuel
System Check fuel filter for clogging
Fuel level
○
○
Fuel tube replacement
Lights &
Winker
Operation
Winking action, dirt and
damage
Buzzer &
Steering Lock Operation
Rearview Mirror
Rearview mirror position
& Reflector
Reflector &
Dirt and damage
License Plate
Counter
Operation
Exhaust
Muffler
○
○
Rearview
Mirror
○
○
○
Joint looseness and damage
○
Exhaust muffler performance
○
Body & Frame Looseness and damage
Abnormal
Conditions
Check if the abnormal
Happened Last conditions occur again
Time
Lubrication points
3-3
Every 4 years
○
○
○
○
Lubrication points
Others
Remove carbon deposits on
combustion chamber,
breather hole and exhaust
muffler
ZX /SCOUT 50
○
○
○
BRAKE DRUM/SHOE
Brake Shoe Wear
Replace the brake shoes if the arrow on the
brake arm aligns with reference mark“ ” on
the brake panel when the brake is fully
applied.
Brake Drum Wear/Damage
Check the brake drum appearance for
damage. Check if the brake lining wear is
within the specified service limit. Check
the brake operation for abnormal noise and
brake drum inside for wear or damage.
BRAKE DISK/LINING
Brake Disk Surface and Brake Pad
Wear
Check the brake disk surface for scratch.
Check if the brake pad wear is within the
specified service limit.
“ ” Marks
Adjusting Nuts
<Front>
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 Service
Limit Mark
Brake Disk
3-4
3. LUBRICATION SYSTEM
Brake Master Cylinder
MOVING DEVICE
TIRES
Tire Pressure
Check the tire pressure.
Tire pressure should be checked when
tires are cold.
Tire Pressure (one rider)
Front: 1.50 kg/cm²
Rear: 1.75 kg/cm²
Tire Size:
Front: 120/70-12
Rear: 120/70-12
Axle Nut/Axle Shaft Looseness
Check the front and rear axle nuts for
looseness.
If the axle nuts are loose, tighten them to
the specified torques.
Torques:
Front: 5.0 7.0kg-m
Rear: 11.0 13.0kg-m
Wheel Rim/Spoke Plate Damage
Check the wheel rim and spoke plate for
wear or damage and measure the rim
runout.
Axle Nut
Rear Wheel
3-5
Axle Nut
DAMPING DEVICE
SHOCK ABSORBERS
Oil Leak/Damage
Fully apply the front brake and check the
action of the front shock absorber by
compressing it several times.
Check the entire shock absorber assembly
for looseness or damage.
Check the action of the rear shock absorber
by compressing it several times.
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. If the 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.
3-6
When the engine is running at the specified rpm,
the ignition timing is correct if the “F” mark on
the flywheel aligns with the index mark on the
crankcase within ±2°.
Ignition Timing:
15.5°±2°BTDC/2000rpm
IGNITION APPARATUS
Spark Plug
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
Gap, Wear and
Fouling Deposits
0.6-0.7mm
Washer Damage
Cracks
BR8HSA
Bolt
Spark Plug Gap: 0.6 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
t
Remove the right side rail. (Ö12-4)
Remove the A.C. generator fan cover.
(Ö7-3)
Remove the four bolts attaching the fan and
then remove the fan.
Warm up the engine and check the ignition
timing with a timing light.
Index Mark
3-7
F Mark
ENGINE
BODY
At High and Low Speeds
Throttle Stop Screw
The engine must be warm for accurate
idle speed adjustment.
Adjust the idle speed to the specified range
by turning the throttle stop screw and air
screw.
Idle Speed:
2100±100rpm
Air Screw
Air Cleaner
Remove the air cleaner cover by removing
the six air cleaner cover screws.
Remove the air cleaner element.
Screws
Air Cleaner
3-8
LUBRICATION SYSTEM
Oil Filter Cleaning
Disconnect the oil tube at the oil pump side and
allow oil to drain into a clean container.
Remove the tube clip at the oil tank side and
disconnect the oil tube.
Remove the oil filter.
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-40# and squeeze out
excess oil. Reinstall the element.
Wash
Squeeze out
and dry
Cylinder Compression
Warm up the engine before compression
test.
Remove the spark plug and insert a
compression gauge.
Open the throttle valve fully and push the
starter button for 7 8 seconds to test the
compression.
Compression:
11.5kg/cm²
If the compression is low, check for the
following:
• Leaking cylinder head gasket
• Worn piston/cylinder
If the compression is high, it indicates that
carbon deposits have accumulated on the
combustion chamber and the piston head.
Clip
3-9
Soak in oil Squeeze out
excess oil
d
If the oil pump is not synchronized properly,
the following will occur:
• Excessive white smoke or hard starting due to
pump control lever excessively open
• Seized piston due to pump control lever
insufficiently open
Oil Filter
Clean the oil filter screen with compressed
air.
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.
Oil Pump Condition
Filter Screen
Control Lever Aligning Mark
Adjust oil pump control cable after the
throttle grip free play is 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
pump control cable by loosening the control
cable lock nut and turning the adjusting nut.
After adjustment, tighten the lock nut.
Reference tip alignment within 1mm of
index mark on open side is 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.
Lock Nut
Adjusting Nut
3-10
Headlight
Adjust the headlight beam by loosening the
headlight adjusting bolt and moving the
adjusting bolt forward and backward to a
proper position. Tighten the adjusting bolt.
FUEL SYSTEM
Throttle Grip Free Play
Measure the throttle grip free play.
Free Play: 2 6mm
If the throttle grip free play does not fall
within the specified range, adjust by
loosening the lock nut and turning the
adjusting nut.
Lock Nut
Adjusting Nut
OTHERS
LIGHTS
3-11
Headlight Adjusting Bolt
3-12
ZX /SCOUT 50
4
__________________________________________________________________________________
__________________________________________________________________________________
4
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
LUBRICATION SYSTEM
__________________________________________________________________________________
SERVICE INFORMATION ................................................................ 4-2
OIL PUMP REMOVAL....................................................................... 4-3
OIL PUMP INSPECTION ................................................................... 4-3
OIL PUMP INSTALLATION ............................................................. 4-4
OIL PUMP BLEEDING....................................................................... 4-5
OIL TANK ........................................................................................... 4-6
4-0
LUBRICATION SYSTEM
4-1
ZX /SCOUT 50
ZX /SCOUT 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 the oil is disconnected, refill the oil line with motor oil before connecting it.
SPECIFICATIONS
• Recommended Motor Oil: SAE20W20# 2-stroke Motor Oil
• Oil Capacity
: 0.80 liter
Light comes on : 0.25 liter
TROUBLESHOOTING
Excessive white smoke or carbon deposits on spark plug
• Oil pump not properly synchronized (excessive oil)
• Poor quality oil
Engine overheating
• Oil pump not properly adjusted (insufficient oiling)
• Poor quality oil
Seized piston
• No oil in tank or clogged oil line
• Oil pump not properly adjusted (insufficient oiling)
• Air in oil line
• Faulty oil pump
Oil not flowing out of tank to engine
• Clogged oil tank cap breather hole
• Clogged oil filter
4-2
OIL PUMP REMOVAL
ZX /SCOUT 50
Oil Outlet Line
Oil Pump
Oil Inlet Line
Control Cable
Do not allow foreign matters to enter the
crankcase. Before removing the oil
pump, clean the oil pump and crankcase
surfaces.
Remove the met-in box. (Ö12-4)
Control Cable plate
Disconnect 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.
O-ring
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
Control Lever
Pinion
ZX /SCOUT 50
OIL PUMP INSTALLATION
• Lubricate the O-ring with grease or
engine oil before installation.
• Make sure that the oil pump is inserted
into the crankcase.
• Apply molybdenum disulfide or
grease to the pump pinion.
Grease or Engine Oil
Install the oil pump onto the crankcase.
Oil Outlet Line
Install the oil 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
ZX /SCOUT 50
Oil Outlet Line
OIL PUMP BLEEDING
• Air in the oil lines will block oil flow
and result in severe engine damage.
• Bleed air from the oil lines and oil
pump whenever the oil lines or pump
have been removed or there is air in
the oil lines.
Oil Pump
OIL INLET LINE/OIL PUMP BLEEDING
Fill the oil tank with recommended oil.
Place a shop towel around the oil pump.
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 1
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.
4-5
Oil Tube
ZX /SCOUT 50
OIL TANK
OIL TANK REMOVAL
Remove the rear carrier. (Ö12-5)
Remove the frame body cover. (Ö12-5)
Remove the oil meter connector.
Remove the two bolts attaching the oil tank.
Disconnect the oil inlet line.
Drain the oil inside the oil tank into a clean
container.
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
5. ENGINE REMOVAL/INSTALLATION
ZX / SCOUT
5
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__________________________________________________________________________________
__________________________________________________________________________________
5
__________________________________________________________________________________
__________________________________________________________________________________
ENGINE REMOVAL/INSTALLATION
__________________________________________________________________________________
ENGINE REMOVAL .......................................................................... 5-2
ENGINE INSTALLATION ................................................................. 5-4
5-0
ZX / SCOUT
SERVICE INFORMATION
• Parts requiring engine removal for servicing:
Crankcase
Crankshaft
TORQUE VALUES
Engine mounting bolt
4.5 5.5kg-m
Rear shock absorber lower mount bolt 2.4 3.0kg-m
Engine hanger bracket bolt
3.5 4.5kg-m
4.5 5.5kg-m
3.5 4.5kg-m
4.5 5.5kg-m
5-1
ENGINE REMOVAL
ZX / SCOUT
Air Cleaner Case
Band
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.
Carburetor Cap
Disconnect the oil pump control cable from
the pump body.
pump.
Oil Inlet Line
Bolt
AC Generator Wire
Connector
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.
Oil Pump Control Cable
Spark Plug Cap
Remove the spark plug cap.
5-2
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.
ZX / SCOUT
Rear Shock Absorber Lower Mount Bolt
Clamp
Rear Brake Cable
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 Mounting Nuts
ENGINE HANGER BRACKET
REMOVAL
Remove the engine hanger bracket bolt and
engine hanger bracket.
The installation sequence is the reserve of
removal.
Torque: 3.5 4.5kg-m
Engine Hanger Bracket Bolt
5-3
ZX / SCOUT
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.
• Throttle cable
• Oil pump control cable (Ö3-10)
• Rear brake cable (Ö3-4)
• Oil pump bleeding (Ö4-5)
5-4
5-5
ZX / SCOUT
6. CYLINDER HEAD/CYLINDER/PISTON
ZX / SCOUT
6
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
6
__________________________________________________________________________________
CYLINDER HEAD/CYLINDER/PISTON
__________________________________________________________________________________
CYLINDER HEAD.............................................................................. 6-3
CYLINDER/PISTON........................................................................... 6-6
6-0
ZX / SCOUT
Torque: 1.5 1.7kg-m
Torque: 1.1 1.7kg-m (cold)
6-1
ZX / SCOUT
SERVICE INFORMATION
• 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.
SPECIFICATIONS
Item
Cylinder head warpage
Piston O.D.(5mm from bottom of piston
Standard (mm)
Service Limit (mm)
SC10AS
SC10AS
⎯
0.10
38.955 38.970
38.90
Cylinder-to- piston clearance
0.10
Piston pin hole I.D.
Piston pin O.D.
Piston-to-piston pin clearance
Piston ring end gap (top/second)
Connecting rod small end I.D.
Cylinder bore
TORQUE VALUES
Cylinder head bolt
Exhaust muffler joint lock nut
Exhaust muffler lock bolt
Spark plug
1.5
1.0
3.0
1.1
12.002 12.008
12.03
11.994 12.0
11.98
←
←
0.10 0.25
0.40
17.005 17.017
17.03
39.0 39.025
39.05
1.7kg-m
1.4kg-m
3.6kg-m
1.7kg-m
●TROUBLESHOOTING
Compression too low, hard starting
or poor performance at low speed
• Leaking cylinder head gasket
• Loose spark plug
• Worn, stuck or broken piston and piston rings
• Worn or damaged cylinder and piston
Compression too high, overheating
or knocking
• Excessive carbon build-up in cylinder head
or on piston head
Abnormal noisy piston
• Worn cylinder and piston
• Worn piston pin or piston pin hole
• Worn connecting rod small end bearing
Abnormal noisy piston rings
• Worn, stuck or broken piston rings
• Worn or damaged cylinder
6-2
CYLINDER HEAD
ZX / SCOUT
Spark Plug Cap
REMOVAL
Remove the rear carrier.
Fan Cover/Engine Hood
Remove the spark plug cap.
Remove the three bolts attaching the fan
cover to remove the fan cover.
Remove the two joint lock nuts on the front
of the exhaust muffler and then remove the
two exhaust muffler lock bolts.
Remove the bolt attaching the engine hood
to remove the engine hood.
removal.
When installing the exhaust muffler,
first tighten the two nuts on the front
and then tighten the two bolts.
Bolts
Cylinder head Bolts
Remove the spark plug.
Remove the cylinder head bolts and the
cylinder head.
Loosen the bolts diagonally in 2 or 3
times.
Remove the cylinder head gasket.
Cylinder Head
6-3
Spark Plug
COMBUSTION CHAMBER
DECABONIZING
Remove the carbon deposits from the
combustion chamber
ZX / SCOUT
Combustion Chamber
Avoid damaging the combustion
cham-ber wall and cylinder mating
f
Mating Surface
CYLINDER HEAD INSPECTION
Check the cylinder head for warpage with a
straight edge and feeler gauge.
Service Limit:
0.10mm replace if over
CYLINDER HEAD INSTALLATION
Install the cylinder head on the cylinder
properly.
Cylinder head Gasket
Be careful not to damage the mating
surfaces.
Install a new cylinder head gasket onto the
cylinder.
6-4
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
ZX / SCOUT
Cylinder head Bolts
Cylinder Head
Spark Plug
Spark Plug
Engine Hood
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
Bolt
Bolts
6-5
CYLINDER/PISTON
ZX / SCOUT
Joint Lock Nuts
Cylinder
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 gasket.
Do not pry between the cylinder and
crankcase or strike the fins.
Piston Pin
Piston
PISTON REMOVAL
Remove the piston pin clip to remove the
piston pin and 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
f
f lli i t th
k
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
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:
Inspect the top of the cylinder for warpage.
Service Limit:
6-7
ZX / SCOUT
ZX / SCOUT
A Mark Nuts
The cylinder has an A mark or no mark
on it. When replacing the cylinder
with a new one, use a cylinder having
the same mark as the old one.
Measure the piston O.D. at a point 5mm
from the bottom of the piston skirt.
Service Limit:
38.90mm replace if below
Measure the piston-to-cylinder clearance.
Service Limit:
Measure the piston pin hole I.D.
Service Limit:
Measure the piston pin O.D.
Service Limit:
Measure the piston-to-piston pin clearance.
Service Limit:
6-8
ZX / SCOUT
PISTON RING INSPECTION
Measure each piston ring end gap.
Service Limits: Top/Second
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 the connecting road small end I.D.
Service Limit:
<Small End I.D. Measurement>
PISTON/CYLINDER INSTALLATION
First install the expander in the second ring
groove.
Then install the top and second rings in
their respective ring grooves.
The piston rings should be pressed into the
grooves with even force.
After installation, check and make sure that
each ring is flush with the piston at several
points around the ring.
A ring that will not compress means that
the ring groove has carbon deposits in it
and should be cleaned.
6-9
piston
Top ring
Sencond ring
expander
ZX / SCOUT
Install a new cylinder gasket on the mating
surface between the cylinder and crankcase.
Cylinder Gasket
Make sure that the ring end gaps are
aligned with the piston ring pins in the ring
grooves.
Ring Pins
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: 1.0 1.4kg-m
Tighten the exhaust muffler lock bolts.
Torque: 3.0 3.6kg-m
Install the frame covers.
6-10
7. A.C. GENERATOR
ZX / SCOUT
7
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
A.C. GENERATOR
7
__________________________________________________________________________________
A.C. GENERATOR REMOVAL......................................................... 7-3
A.C. GENERATOR INSTALLATION ............................................... 7-4
7-0
7. A.C. GENERATOR
ZX / SCOUT
Torque: 0.8 1.2kg-m
Torque: 3.5 4.0kg-m
Torque: 0.6 1.0kg-m
Torque: 0.8 1.2kg-m
7-1
7. A.C. GENERATOR
ZX / SCOUT
SERVICE INFORMATION
• 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
7-2
7. A.C. GENERATOR
ZX / SCOUT
Bolts
A.C. GENERATOR REMOVAL
Remove the three bolts attaching the fan
cover to remove the fan cover.
Fan Cover
Bolt
Remove the cooling fan by removing the
four bolts.
Cooling Fan
Nut
Hold the flywheel with an universal holder
and then remove the flywheel nut.
Universal Holder
7-3
7. A.C. GENERATOR
Remove the A.C. generator flywheel using
the flywheel puller.
ZX / SCOUT
Lock Nut Wrench
Flywheel Puller
A.C. Generator Wire Connector
Remove the A.C. generator wire connector.
Stator
Wire Clamp
Remove the two pulser coil bolts and pulser
coil from the right crankcase.
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
coil wire clamp onto the right crankcase,
and then install the pulser coil.
Pulser Coil
7-4
7. A.C. GENERATOR
Connect the A.C. generator wire connector.
ZX / SCOUT
A.C. Generator Wire Connector
Woodruff Key
Clean the taper hole in the flywheel off any
burrs and dirt.
Install the woodruff key in the crankshaft
keyway.
Install the flywheel onto the crankshaft with
the flywheel groove aligned with the
crankshaft woodruff key.
Hold the flywheel with the universal holder
and install the flywheel flange nut.
Torque: 3.5 4.0kg-m
Start the engine and check the ignition
timing. (Ö3-7)
Install other removed parts in the reserve
order of removal.
Universal Holder
7-5
8. KICK STARTER/DRIVE PULLEY/
CLUTCH/DRIVEN PULLEY
ZX / SCOUT
8
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
KICK STARTER/DRIVE PULLEY/
8
__________________________________________________________________________________
TROUBLESHOOTING ....................................................................... 8- 2
KICK STARTER.................................................................................. 8- 3
DRIVE BELT ....................................................................................... 8- 7
DRIVE PULLEY.................................................................................. 8- 9
STARTER PINION.............................................................................. 8-11
CLUTCH/DRIVEN PULLEY.............................................................. 8-12
8-0
ZX / SCOUT
MODEL SC10AS
Torque:
5.0 6.0kg-m
Torque:
3.5 4.5kg-m
8-1
ZX / SCOUT
SERVICE INFORMATION
• Avoid getting grease and oil on the drive belt and pulley faces.
SPECIFICATIONS
SC10AS
Standard (mm) Service Limit (mm)
Item
Drive pulley collar O.D.
Movable drive face I.D.
20.01 20.025
24.24
20.035 20.085
19.97
13.0
12.4
107 107.2
107.5
87.9
82.6
33.965 33.985
33.94
34.0 34.25
34.06
18
17
Weight roller O.D.
Clutch outer I.D.
Driven face spring free length
Driven face O.D.
Movable driven face I.D.
Drive belt width
TORQUE VALUES
Drive face nut
Clutch outer nut
Clutch drive plate nut
3.5 4.0kg-m
3.5 4.5kg-m
5.0 6.0kg-m
SPECIAL TOOLS
Lock nut wrench, 39mm
Clutch spring compressor
Bearing outer driver 37x40mm
One-way clutch puller
Universal holder
Lock nut socket wrench, 32mm
Bearing driver pilot, 17mm
Outer driver, 24x26mm
TROUBLESHOOTING
Engine starts but motorcycle won‘t move
• Worn drive belt
• Broken ramp plate
• Worn or damaged clutch lining
Poor performance at high speed or
lack of power
• Worn drive belt
• Weak driven face spring
• Worn weight roller
• Faulty driven face
Engine stalls or motorcycle creeps
• Broken clutch weight spring
8-2
ZX / SCOUT
KICK STARTER
LEFT CRANKCASE COVER REMOVAL
Remove the drive belt cooling air tube
connector circlip.
Remove the nine left crankcase cover bolts,
left crankcase cover and dowel pins.
Inspect the left crankcase cover seal rubber
for damage or deterioration.
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
8-3
Kick Starter Driven Gear
ZX / SCOUT
Remove the kick starter spindle and return
spring from the left crankcase cover.
Remove the kick starter spindle bushing.
Spindle
Return Spring
KICK STARTER SPINDLE INSPECTION
Inspect the kick starter spindle and gear for
wear or damage.
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.
8-4
ZX / SCOUT
Inspect the kick starter spindle and driven
gear forcing parts for wear or damage.
Kick Starter Spindle Forcing Part
Kick Starter Driven Gear Forcing Part
KICK STARTER INSTALLATION
Install the kick starter spindle bushing and
return spring onto the left crankcase cover.
If the hooks of the return spring can not
be installed properly, use a screw driver
to press them into their locations
respectively.
Return Spring
Friction Spring
Properly install the kick starter driven gear
and friction spring as the figure shown.
8-5
ZX / SCOUT
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.
8-6
ZX / SCOUT
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:
Use specified genuine parts for
replace-ment.
Clutch Outer
Clutch Outer Nut
REPLACEMENT
Remove the nine left crankcase cover bolts
and left crankcase cover. (Ö8-3)
Hold the clutch outer with the universal
holder and remove the 14mm clutch outer
nut and clutch outer.
Ratchet
Drive Face
Hold the drive pulley with the holder and
remove the drive face nut.
Remove the starting ratchet.
Remove the drive pulley face.
Drive Face Nut
8-7
ZX / SCOUT
Clutch/Driven Pulley
Remove the drive belt from the clutch/
driven pulley.
Drive Belt
DRIVE BELT INSTALLATION
Turn the driven pulley clockwise and lift it
up to expand the drive belt groove and then
install a new drive belt.
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
and washer, then tighten the drive face nut.
Torque: 3.5 4.0kg-m
When installing the drive face nut, make
sure that the tooth spaces of the drive
pulley face and starting ratchet align
with the teeth of the crankshaft.
Starting Ratchet
Washer
8-8
ZX / SCOUT
DRIVE PULLEY
Drive Pulley Face
Starting Ratchet
REMOVAL
Hold the drive pulley with the holder and
remove the drive face nut.
Remove the starting ratchet, washer and
drive pulley face.
Drive Face Nut
Movable Drive Face
MOVABLE DRIVE FACE
DISASSEMBLY
Remove the movable drive face and drive
pulley collar from the crankshaft.
Drive Pulley Collar
Ramp Plate
Remove the ramp plate.
8-9
ZX / SCOUT
Remove the weight rollers.
Weight Roller
MOVABLE DRIVE FACE INSPECTION
Check each weight roller for wear or
damage.
Measure each roller O.D.
Service Limit:
Movable Drive Face
DRIVE PULLEY INSTALLATION
Install the drive pulley collar and movable
drive face onto the crankshaft.
Drive Pulley Collar
8-10
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
ZX / SCOUT
Drive Pulley Face
Keep grease or oil off the drive belt and
drive pulley faces.
Drive Face Nut
Starting Ratchet
STARTER PINION
REMOVAL
Remove the left crankcase cover. (Ö8-3)
Remove the drive pulley. (Ö8-9)
Remove the starter pinion.
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 removal.
Starter Pinion
8-11
ZX / SCOUT
Clutch Outer
14mm Clutch Outer Nut
CLUTCH/DRIVEN PULLEY REMOVAL
Remove the drive pulley. (Ö8-9)
holder and remove the 14mm clutch outer
nut.
Remove the clutch outer.
Universal Holder
Remove the clutch/driven pulley.
Remove the drive belt from the
clutch/driven pulley.
Lock Nut Wrench, 39mm
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
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.
INSPECTION
Inspect the clutch outer for wear or damage.
Measure the clutch outer I.D.
Service Limit:
8-13
ZX / SCOUT
ZX / SCOUT
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:
Check the driven face assembly for wear or
damage.
Measure the driven face O.D.
Check the movable driven face for wear or
damage.
Measure the movable driven face I.D.
Check the guide roller pins for stepped
wear.
8-14
ZX / SCOUT
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.
Snap Ring
Remove the snap ring and drive the outer
bearing out of the driven face.
Outer Bearing
Bearing Outer Driver, 37x40mm
Drive a new outer bearing into the driven
face with the sealed end facing up.
Seat the snap ring in its groove.
Pack all bearing cavities with 5.0 5.6g
grease.
Specified grease: 230 Heat-resistant
grease
8-15
ZX / SCOUT
Drive in a new needle bearing into the
driven face with the mark facing up.
Bearing Driver Pilot
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.
8-16
ZX / SCOUT
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
INSTALLATION
Install the drive belt on the clutch/driven
pulley and then install the clutch/driven
pulley onto the drive shaft.
Clutch Outer
Install the clutch outer.
holder.
Install and tighten the 10mm clutch outer
nut.
Torque: 3.5 4.5kg-m
Install the left crankcase cover. (Ö8-6)
Universal Holder
8-17
9. FINAL REDUCTION
ZX / SCOUT
50
9
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
FINAL REDUCTION
__________________________________________________________________________________
FINAL REDUCTION DISASSEMBLY ............................................. 9-3
9
FINAL REDUCTION INSPECTION.................................................. 9-3
FINAL REDUCTION ASSEMBLY.................................................... 9-6
9-0
9. FINAL REDUCTION
9-1
ZX / SCOUT
9. FINAL REDUCTION
ZX / SCOUT
50
SERVICE INFORMATION
Specified Oil: SAE90#
At disassembly: 0.12 liter
At change:
0.1 liter
SPECIAL TOOLS
Crankcase assembly shaft
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
9-2
9. FINAL REDUCTION
ZX / SCOUT
Bolts
FINAL REDUCTION
DISAS-SEMBLY
Remove the rear wheel. (Ö14-3)
Remove the left crankcase cover. (Ö8-3)
Remove the clutch/driven pulley. (Ö8-7)
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
Driver shift
Remove the final gear and countershaft.
Countershaft
Final Gear
FINAL REDUCTION INSPECTION
Inspect the countershaft and gear for wear
or damage.
Countershaft
9-3
Dowel Pin
9. FINAL REDUCTION
ZX / SCOUT
50
Inspect the final gear and final shaft for
wear, damage or seizure.
Final Shaft
Check the left crankcase bearings for
excessive play and inspect the oil seal for
wear or damage.
Drive Shaft Bearing
Oil Seal
Inspect the drive shaft and gear for wear or
damage.
Check the transmission case cover bearings
for excessive play and inspect the final
shaft bearing oil seal for wear or damage.
Do not remove the transmission case
cover except for necessary part
replace-ment. When replacing the
drive shaft, also replace the bearing and
il
l
9-4
9. FINAL REDUCTION
BEARING REPLACEMENT
(Transmission Case Cover)
Remove the transmission case cover
bearings using the bearing remover.
Remove the final shaft oil seal.
ZX / SCOUT
Drive Shaft Bearing
Bearing Remover Set
Bearing Outer Driver Handle A
Drive new bearings into the transmission
case cover.
BEARING REPLACEMENT (Left
Crankcase Cover)
Remove the drive shaft.
Remove the drive shaft oil seal.
Remove the left crankcase bearings using
the bearing remover.
Bearing Remover Set, 12mm
9-5
9. FINAL REDUCTION
ZX / SCOUT
50
Drive new bearings into the left crankcase.
Install a new drive shaft oil seal.
Bearing Outer Driver
FINAL REDUCTION ASSEMBLY
Install the drive shaft into the left
crankcase.
Drive Shaft
Install the final gear and final shaft into the
left crankcase.
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 a new gasket.
ZX / SCOUT
Dowel Pins
Countershaft Resin Washer
Install the transmission case cover.
Transmission Case Cover
Install and tighten the transmission case
cover bolts.
Install the clutch/driven pulley. (Ö8-17)
Install other removed parts in the reverse
order of removal.
Bolts
9-7
9. FINAL REDUCTION
ZX / SCOUT
50
After installation, fill the transmission case
with the specified oil.
• Place the motorcycle on its main stand
on level ground.
• Check the sealing washer for wear or
damage.
Specified Gear Oil: SAE90#
Oil Capacity: at disassembly: 0.12 liter
at change: 0.1 liter
Install and tighten the oil check bolt.
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
9-8
10. CRANKCASE/CRANKSHAFT
ZX / SCOUT
10
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
CRANKCASE/CRANKSHAFT
__________________________________________________________________________________
CRANKCASE SEPARATION ............................................................ 10-3
CRANKSHAFT REMOVAL............................................................... 10-3
CRANKSHAFT INSPECTION ........................................................... 10-4
CRANKSHAFT INSTALLATION ..................................................... 10-5
CRANKCASE ASSEMBLY................................................................ 10-7
10
10-0
Torque: 0.8 1.2kg-m
10-1
ZX / SCOUT
ZX / SCOUT
SERVICE INFORMATION
• This section covers crankcase separation to service the crankshaft.
• The following parts must be removed before separating the crankcase.
Engine (ÖSection 5)
Driven pulley (ÖSection 8)
Carburetor (ÖSection 11)
A.C. generator (ÖSection 7)
Oil pump (ÖSection 4)
Cylinder head/cylinder (ÖSection 6)
Reed valve (ÖSection 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
Item
SC10AS
Standard (mm) Service Limit (mm)
Connecting rod big end side
clearance
Connecting rod big end radial
clearance
⎯
0.60
⎯
0.04
Crankshaft runout A/B
⎯
0.15/0.10
SPECIAL TOOLS
Crankcase puller
Crankcase assembly tool
Bearing outer driver handle A
TROUBLESHOOTING
Abnormal engine noise
• Excessive crank journal bearing play
• Excessive crankpin bearing play
• Excessive transmission bearing play
10-2
ZX / SCOUT
CRANKCASE SEPARATION
Remove the crankcase attaching bolts.
Crankcase Puller
Attach the crankcase puller on the right
crankcase and remove the right crankcase
from the left crankcase.
Crankcase Puller
CRANKSHAFT REMOVAL
Attach the crankcase puller on the left
crankcase and remove the crankshaft from
the left crankcase.
10-3
ZX / SCOUT
Remove the remaining bearing on the
crankshaft side using the universal bearing
puller.
Universal Bearing Puller
CRANKSHAFT INSPECTION
Measure the connecting rod big end side
clearance.
Service Limit: 0.6mm replace if over
Measure the connecting rod big end radial
clearance at two points in the X and Y
directions.
10-4
ZX / SCOUT
Measure the crankshaft runout.
Service Limit
A
B
0.150mm
replace if over
0.100mm
replace if over
Check the crankshaft bearings for excessive
play. The bearings must be replaced if
they are noisy or have excessive play.
Play
Play
Axial
CRANKSHAFT INSTALLATION
Wash the crankshaft in cleaning solvent and
then check for cracks or other faults.
10-5
Radial
Drive a new crankshaft bearing into the
right crankcase.
ZX / SCOUT
Bearing Driver Pilot, 17mm
Drive a new crankshaft bearing into the left
crankcase.
Pilot, 20mm
Install the crankshaft into the left
crankcase.
Crankcase Assembly Collar
Crankcase Assembly Tool
10-6
CRANKCASE ASSEMBLY
ZX / SCOUT
Dowel Pins
Install the dowel pins and a new gasket to
the crankcase mating surface.
Assemble the crankcase halves.
The distance between the right crankcase
oil seal and crankcase surface is about
12.5±0.5 mm.
10-7
ZX / SCOUT
Oil Seal
The distance between the left crankcase oil
seal and crankcase surface is about 1.0mm.
1.0mm
Install and tighten the crankcase attaching
bolts.
Bolts
10-8
11. CARBURETOR
ZX / SCOUT
11
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
CARBURETOR
__________________________________________________________________________________
THROTTLE VALVE DISASSEMBLY .............................................. 11- 3
THROTTLE VALVE INSTALLATION............................................. 11- 4
CARBURETOR REMOVAL .............................................................. 11- 5
AUTO BYSTARTER........................................................................... 11- 6
FLOAT CHAMBER ............................................................................ 11- 8
FLOAT LEVEL INSPECTION ........................................................... 11-10
11
CARBURETOR INSTALLATION ..................................................... 11-11
AIR SCREW ADJUSTMENT ............................................................. 11-11
REED VALVE ..................................................................................... 11-12
FUEL TANK ........................................................................................ 11-13
11-0
11. CARBURETOR
11-1
ZX / SCOUT
11. CARBURETOR
ZX / SCOUT
SERVICE INFORMATION
• 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
Venturi dia.
Identification number
14mm
0.14A
Float level
5.0mm
Main jet
#80
Slow jet
#35
Air screw opening
1±¼
Idle speed
Throttle grip free play
2100±100rpm
2 6mm
SPECIAL TOOL
Float level gauge
TROUBLESHOOTING
Engine does not start
• No fuel in tank
• Too much fuel getting to cylinder
• Clogged fuel filter
• Clogged air cleaner
Lean mixture
• Clogged fuel jets
• Faulty float valve
• Clogged fuel cap vent
• Float level too low
• Clogged fuel filter
• Bent, kinked or restricted fuel line
Engine idles roughly, stalls or runs poorly
• Incorrect idle speed
• Ignition malfunction
• Intake air leaks
• Compression too low
• Fuel contaminated
• Incorrectly adjusted air screw
• Faulty reed valve
• Incorrect float level
• Clogged fuel jets
Rich mixture
• Faulty float valve
• Float level too high
• Clogged air jets
11-2
11. CARBURETOR
ZX / SCOUT
THROTTLE VALVE
DIS-ASSEMBLY
Loosen the carburetor cap and remove the
throttle valve.
Carburetor Cap
Throttle Valve
Disconnect the throttle cable from the
throttle valve.
Rubber Seal
Remove the throttle valve spring,
carburetor cap and rubber seal.
Carburetor Cap
11-3
Spring
11. CARBURETOR
ZX / SCOUT
Remove the jet needle by removing the
needle clip.
Check the jet needle and throttle valve for
wear or damage.
Needle Clip
Needle Retainer
2nd Notch (STD)
Jet Needle
Throttle Valve
Rubber Seal
Carburetor Cap
THROTTLE VALVE
INSTALLA-TION
Install the jet needle on the throttle valve
and secure with the needle clip.
Install the rubber seal on the throttle cable
and then install the carburetor cap and
throttle valve spring.
Throttle Valve Spring
Throttle Valve
Connect the throttle cable to the throttle
valve.
Throttle Cable
11-4
11. CARBURETOR
ZX / SCOUT
Groove
Install the throttle valve by aligning the
groove in the throttle valve with the throttle
stop screw.
Throttle Stop Screw
Carburetor Cap
Tighten the carburetor cap.
After installation, perform the following
adjustments and inspections.
• Throttle cable free play (Ö3-11)
• Idle speed adjustment (Ö3-8)
Install the met-in box.
CARBURETOR REMOVAL
Throttle Cable
Remove the air cleaner by removing the air
cleaner band screw and attaching bolts.
Disconnect the fuel tube.
Loosen the drain bolt to drain fuel from the
carburetor.
Disconnect the auto bystarter wire
connector.
Remove the two carburetor lock nuts.
Drain Bolt
11-5
11. CARBURETOR
Remove the carburetor.
ZX / SCOUT
Bolts
AUTO BYSTARTER
AUTO BYSTARTER INSPECTION
Measure the resistance between the auto
bystarter wire terminals.
Resistance: 5Ω (10 minutes minimum after
stopping the engine)
If the resistance exceeds 5Ω, replace the
auto bystarter with a new one.
After the engine stops for 30 minutes,
connect a hose to the fuel enriching circuit
and blow the hose with mouth.
If air cannot be blown into the hose
(clogged), the auto bystarter is faulty.
Replace it with a new one.
11-6
11. CARBURETOR
ZX / SCOUT
Connect the auto bystarter yellow wire to
the battery positive (+) terminal and green/
black wire to the battery negative (-)
terminal and wait 5 minutes.
Connect a hose to the fuel enriching circuit
and blow the hose with mouth.
If air can be blown into the hose, the auto
bystarter is faulty and replace it with a new
one.
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 Needle
11-7
Bystarter Valve
11. CARBURETOR
AUTO BYSTARTER INSTALLATION
Install the auto bystarter into the carburetor
body until it bottoms..
Install the set plate and then tighten the two
screws.
ZX / SCOUT
Screws
Auto Bystarter
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
11. CARBURETOR
FLOAT/FLOAT VALVE INSPECTION
Inspect the float for damage or fuel inside
the float.
Check the float valve seat for wear or
damage.
ZX / SCOUT
Float Valve
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
CARBURETOR PASSAGES CLEANING
Blow compressed air through all passages
of the carburetor body with an air gun.
11-9
Air Screw
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.
ZX / SCOUT
Main Jet
Throttle Stop Screw
Air Screw
Install the float valve, float and float pin.
Tighten the float screw securely.
Float Pin
FLOAT LEVEL INSPECTION
Slightly tilt the carburetor and measure the
float level with the float valve just
connecting the float arm.
Float Level: 5.0mm
Replace the float if the level is out of the
specified level range.
Install the O-ring.
Check the operation of the float and install
the float chamber.
Tighten the screws.
11-10
11. CARBURETOR
ZX / SCOUT
CARBURETOR INSTALLATION
Check the carburetor insulator and O-ring
for wear or damage.
Install the carburetor and insulator onto the
intake manifold and tighten the two lock
nuts.
Connect the fuel tube and auto bystarter
wire connector.
Install the carburetor cap. (Ö11-4)
Install the air cleaner onto the carburetor
and tighten the band screw.
Install the met-in box. (Ö12-4)
Insulator
Carburetor Cap
AIR SCREW ADJUSTMENT
Turn the air screw clockwise until it seats
lightly and back it to the specification
given.
Air Screw Opening:
1±¼ turns
Start the engine and turn the air screw in or
out slowly to obtain the highest engine
speed.
Air Screw
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 ±½ turn makes no difference to the
engine performance, check other related
items.
11-11
Throttle Stop Screw
11. CARBURETOR
ZX / SCOUT
Bolts
REED VALVE
REMOVAL
Remove the four intake manifold bolts and
gasket.
Remove the reed valve and gasket.
Intake Manifold
Reed Stopper
INSPECTION
Check the reed valve for damaged or weak
reeds.
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
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. (Ö16-2)
Replace the fuel unit if necessary. (Ö16-2)
ZX / SCOUT
Fuel Unit
Fuel Tank Cap
Fuel Tank
Auto Fuel Valve
Fuel Tube
11-13
Vacuum Tube
12. FRAME COVERS
ZX / SCOUT
12
12
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
FRAME COVERS
__________________________________________________________________________________
FRAME COVERS REMOVAL........................................................... 12-3
12-0
12. FRAME COVERS
ASSEMBLY DRAWING
12-1
ZX / SCOUT
12. FRAME COVERS
ZX / SCOUT
SERVICE INFORMATION
• When removing frame covers, use care not to pull them by force because the cover joint claws
may be damaged.
Items Related for Removal
• Handlebar front cover
• Front cover
• Handlebar rear cover
• Frame body cover
• Floor board
• Front tool box
Handlebar rear cover
Headlight wire
Speedometer cable and instrument light
wire connectors, etc.
Met-in box, rear carrier
Rear carrier, frame body cover, right and left
side rails, battery
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.
removal.
During removal, be careful not to pull
the joint claws forcibly and remove the
front cover downward.
HANDLEBAR FRONT/REAR COVER
REMOVAL
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.
removal.
FRONT RIGHT & LEFT LOWER
COVERS REMOVAL
First remove the front cover.
Remove the right and left side rails by
removing the two screws for each rail.
Remove the two bolts and three screws
attaching each of the front right and left lower
covers.
Remove the front right and left lower covers.
removal.
When removing the right and left side
rails, pull them backward not to damage
the joint claws.
12-3
Bolt
Screw
Bolt
Handlebar Rear Cover
Bolts
12. FRAME COVERS
ZX / SCOUT
Bolts
FLOOR BOARD REMOVAL
Remove the right and left side rails. (Ö12-3)
Remove the battery cover and battery.
Remove the four bolts attaching the floor board
to remove the floor board.
removal.
When removing the battery, first
disconnect the battery negative (-) cable
and then the positive (+) cable.
Floor Board
Bolt
Front Tool Box
FRONT TOOL BOX REMOVAL
Remove the floor board. (Ö12-3)
(Ö12-3)
Remove the three bolts attaching the front tool
box.
Remove the front tool box
removal.
Front Tool Box
Bolts
BOTTOM COVER REMOVAL
Remove the right and left side rails. (Ö12-3)
Remove the front cover. (Ö12-3)
(Ö12-3)
Remove the three bolts attaching each side of
the bottom cover.
Remove the bottom cover.
removal.
Met-in Box
Bottom Cover
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 the oil tank cap and rubber packing.
Remove the met-in box.
removal .
Do not allow flames or sparks near the
working area.
Bolt
Bolts
Nuts
12-4
12. FRAME COVERS
Bolts
FRAME BODY COVER REMOVAL
Remove the three bolts attaching the rear
carrier.
removal.
Rear Carrier
FRONT FENDER REMOVAL
Remove two bolts attaching each side of the
front fender.
Remove the front fender.
removal.
Screws
Screws
Front Fender
12-5
13. STEERINGHANDLEBAR/FRONTWHEEL/FRONT
BRAKE/FRONTSHOCKABSORBER/FRONTFORK
ZX / SCOUT
13
__________________________________________________________________________________
13
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
STEERING HANDLEBAR/FRONT WHEEL/FRONT
BRAKE/FRONT SHOCK ABSORBER/FRONT FORK
__________________________________________________________________________________
STEERING HANDLEBAR ................................................................. 13- 3
FRONT WHEEL .................................................................................. 13- 5
FRONT BRAKE (DISK BRAKE)....................................................... 13- 9
FRONT SHOCK ABSORBER ............................................................ 13-17
FRONT FORK ..................................................................................... 13-20
13-0
ZX / SCOUT
3.3kg-m
4.5kg-m
6.0kg-m
SERVICE INFORMATION
13-1
2.7kg-m
ZX / SCOUT
SPECIFICATIONS
Item
Axle shaft runout
Radial
Axial
Front wheel rim runout
Front brake drum I.D.
Front brake lining thickness
Front shock absorber spring free length
Brake disk thickness
Brake disk runout
Brake master cylinder I.D.
Brake master cylinder piston O.D.
Brake caliper piston O.D.
Brake caliper piston I.D.
TORQUE VALUES
Handlebar lock nut
Steering stem lock nut
Steering top cone race
4.0 5.0kg-m
8.0 12.0kg-m
0.5 1.3kg-m
SPECIAL TOOLS
Lock nut wrench
Lock nut socket wrench
Rear shock absorber remover
Ball race remover
Standard (mm)
⎯
⎯
⎯
110
4.0
200
35 3.8
⎯
12.700 12.743
12.657 12.684
25.400 25.405
25.318 25.368
Service Limit (mm)
0.2
2.0
2.0
111
2.0
182.8
3.0
0.30
12.75
12.64
25.45
25.30
Front damper nut
Front axle nut
Brake arm bolt
1.5 3.0kg-m
5.0 7.0kg-m
0.4 0.7kg-m
Driver handle A
Pilot, 10mm
Bearing puller
Snap ring pliers (close)
Damper compressor
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)
• Air in brake system
• Deteriorated brake fluid
• Contaminated brake disk or disk pad
• Worn brake bushing
• Worn brake master cylinder piston oil seal
• Clogged brake fluid 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
ZX / SCOUT
STEERING HANDLEBAR
REMOVAL
Remove the handlebar front and rear covers.
(Ö12-3)
Remove two bolts attaching the left brake
lever holder.
Remove two bolts attaching the brake
master cylinder (disk brake) to the right
brake lever.
Bolts
Bolts
Bolts
Throttle Cable
Remove the two right handlebar switch
housing bolts and separate the housing.
Disconnect the throttle cable and then
remove the throttle pipe from the handlebar.
Throttle Pipe
Handlebar
Remove the handlebar lock nut to remove
the handlebar.
13-3
INSTALLATION
ZX / SCOUT
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 cable.
Holders
removal.
Install the rear brake lever holder.
Install the front brake master cylinder (disk
brake).
Tab/Groove
FRONT WHEEL
REMOVAL
13-4
ZX / SCOUT
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 ½ of the total indicator
reading.
Axle Nut
13-5
Check the wheel rim runout.
Service Limits:
Radial:
ZX / SCOUT
Axial: 2.0mm replace if over
Turn the wheel bearings and replace them if
they have excessive play or noise.
Play
Play
Axial
DISASSEMBLY
Remove the dust seal.
Radial
Dust Seal
Remove the wheel bearings and distance collar.
13-6
ZX / SCOUT
Pilot, 10mm
ASSEMBLY
Grease
Pilot, 10mm
Pack all bearing cavities with grease.
Drive in the left bearing .
Install the distance collar.
Drive in the right bearing.
Drive the bearing squarely with the
sealed end facing out.
Bearing Puller
13-7
Apply grease to the dust seal lip and install the
dust seal.
Install the side collar.
Axle Nut
ZX / SCOUT
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
Side Collar
HYDRAULIC BRAKE (FRONT BRAKE)
Brake Fluid Replacement/Air Bleeding
Check the brake fluid level on level ground.
• When operating the brake lever, the
brake reservoir cap must be tightened
securely to avoid spill of brake fluid.
• When servicing the brake system, use
shop towels to cover plastic parts and
13-8
ZX / SCOUT
Lower Limit
Bleed Valve
Brake Fluid Bleeding
In order to avoid spill of brake fluid,
connect a transparent hose to the bleed
valve.
Warning
Brake fluid spilled on brake pads or
brake disk will reduce the braking
effect. 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 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
Make sure to bleed air from the brake
system.
Upper Limit
Brake Pad/Disk Replacement
The brake pads must be replaced as a
set to ensure the balance of the brake
disk.
13-9
ZX / SCOUT
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.
Front Brake Caliper
Brake Disk
Measure the brake disk thickness.
Service Limit: 3.0mm
Measure the brake disk runout.
Pad Pin
BRAKE MASTER CYLINDER
Removal
First drain the brake fluid from the hydraulic
brake system.
• When servicing the brake system, use
shop towels to cover rubber and
plastic parts and coated surfaces to
avoid being contaminated by brake
fluid.
• When removing the brake fluid pipe
13-10
ZX / SCOUT
Bolts
Disassembly
Remove the piston rubber cover and snap
ring from the brake master cylinder.
Master Cylinder
Spring
Main Piston
Washer
Snap Ring
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.
13-11
Inspection
Measure the brake master cylinder I.D.
Inspect the master cylinder for scratch or crack.
ZX / SCOUT
Measure the brake master cylinder piston
O.D.
Before assembly, inspect the lst 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 a unit
without exchange.
• When assembling the piston, soak the
cups in brake fluid for a while.
• Install the cups with the cup lips
facing the correct direction.
Install the main piston, spring and snap
ring.
Install the rubber cover.
Install the brake lever.
Place the brake master cylinder on the
handlebar and install the holder with “up” mark
facing up. Be sure to 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
13-12
ZX / SCOUT
Bolts
“Up” Mark
Install the brake fluid pipe with the
attaching bolt and two sealing washers.
Install the handlebar covers. (Ö12-3)
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. (Ö13-10)
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.
Bolt
Punch Mark
13-13
Disassembly
Remove the brake caliper seat from the brake
caliper.
ZX / SCOUT
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 groove with brake fluid.
Be careful not to damage the piston
surface.
Brake Caliper Seat
Check the piston for scratch or wear.
Measure the piston O.D. with a micrometer.
13-14
ZX / SCOUT
Check the caliper cylinder for scratch or
wear and measure the cylinder bore.
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 a clean
shop towel. Apply silicon grease to the
brake caliper seat pin and caliper inside.
Install the brake caliper seat.
Installation
Install the brake caliper and tighten the two
bolts.
Torque: 2.9 3.5kg-m
13-15
ZX / SCOUT
Bolts
Connect the brake fluid pipe to the brake
caliper and tighten the fluid pipe bolt.
Torque: 3.0 4.0kg-m
Fill the brake reservoir with recommended
brake fluid and bleed air from the brake
system. (Ö13-9)
FRONT SHOCK ABSORBER
REMOVAL
Remove the front wheel. (Ö13-5)
Remove the front shock absorber upper mount
bolts.
Loosen the lower mount bolts to remove the
front shock absorbers.
13-16
ZX / SCOUT
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.
Use a vise to hold the front shock absorber tube
and remove the damper from the shock
absorber tube.
When holding the shock absorber tube,
place a shop towel under it and do not
apply too much force.
13-17
ZX / SCOUT
Measure the front shock absorber spring
free length.
Service Limit: Right : 200mm
Left : 200mm
FRONT SHOCK ABSORBER
ASSEMBLY
Damper
Damper Nut
Dust Seal
Circlip
Front Shock
Absorber
Spring
Oil Seal
Damping
Spring
Front Shock
Absorber
Absorber
Tube
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.
13-18
ZX / SCOUT
Damper Nut
Use a vise to hold the front shock absorber.
Tighten the hex bolt.
(Apply locking agent to the washer and
socket hex bolt and install them together.)
Torque: 1.5 3.0kg-m
Specified Oil: ss#8
Oil Capacity: 61cc
Bolt/Washer
Install the circlip.
Install the dust boot.
Circlips
Dust Boot
INSTALLATION
Install the front
shock absorbers
onto the steering
stem.
Install and tighten
the front shock absorber upper mount bolts.
Tighten the lower mount bolts.
13-19
ZX / SCOUT
Install the front wheel. (Ö13-8)
FRONT FORK
REMOVAL
Remove the steering handlebar. (Ö13-3)
Disconnect the speedometer cable and front
brake fluid pipe and remove the front brake
caliper.
Remove the front wheel. (Ö13-5)
Hold the steering stem top cone race and
remove the steering stem lock nut.
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
Mount Bolts
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.
13-20
ZX / SCOUT
Bottom Cone Race
BALL RACE REPLACEMENT
Drive out the ball races.
Drive in new ball races.
Ball Race Remover
Driver Handle A
Be sure to drive the ball races into place
completely.
INSTALLATION
Apply grease to top and bottom ball races and
install 26 steel balls on the top ball race and 29
steel balls on the bottom ball race.
Apply grease to the ball races again and then
install the front fork.
13-21
ZX / SCOUT
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.
Torque: 8.0 12.0kg-m
Install the front wheel. (Ö13-8)
Install the handlebar. (Ö13-4)
Install the speedometer cable.
Lock Nut Wrench
13-22
14. REAR WHEEL/REAR BRAKE/REAR
SHOCK ABSORBER
ZX / SCOUT
14
__________________________________________________________________________________
__________________________________________________________________________________
14
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
REAR WHEEL/REAR BRAKE/REAR
SHOCK ABSORBER
__________________________________________________________________________________
REAR WHEEL..................................................................................... 14-3
REAR BRAKE ..................................................................................... 14-4
REAR SHOCK ABSORBER............................................................... 14-7
14-0
SHOCK ABSORBER
ZX / SCOUT
4.5kg-m
3.0kg-m
11.0kg-m
14-1
ZX / SCOUT
SHOCK ABSORBER
SERVICE INFORMATION
SPECIFICATIONS
Standard (mm)
Item
Rear wheel rim runout
Rear brake drum I.D.
Rear brake lining thickness
Rear shock absorber spring free length
TORQUE VALUES
Rear axle nut
Rear shock absorber upper mount bolt
Rear shock absorber lower mount bolt
Rear shock absorber lower joint nut
110
4.0
235.7
Service Limit (mm)
2.0
111
2.0
218.7
11.0 13.0kg-m
3.5 4.5kg-m
2.4 3.0kg-m
3.5 4.5kg-m (apply locking agent)
SPECIAL TOOL
Rear shock absorber remover
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
SHOCK ABSORBER
REAR WHEEL
ZX / SCOUT
Rear Axle Nut
REMOVAL
nuts.
Remove the two exhaust muffler lock bolts.
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.
Torque values:
Rear axle nut: 11.0 13.0kg-m
14-3
SHOCK ABSORBER
ZX / SCOUT
REAR BRAKE
Remove the rear wheel. (Ö14-3)
Inspect the rear brake drum.
Measure the rear brake drum I.D.
BRAKE LINING INSPECTION
Measure the brake lining thickness.
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
SHOCK ABSORBER
Remove the brake arm bolt to remove the
brake arm, wear indicator plate and felt
seal.
Remove the brake cam.
Brake Arm Bolt
ZX / SCOUT
Wear Indicator Plate
Brake Arm
Brake Cam
Grease
REAR BRAKE ASSEMBLY
Apply grease to the anchor pin and brake
shoe moving parts.
Apply grease to the brake cam and install it.
Apply engine oil to the felt seal and install
it to the brake cam.
Install the wear indicator plate.
Align the wide tooth of the wear
indicator plate with the wide groove on
the brake cam.
Wear Indicator Plate
Punch Mark
Install 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
Brake Arm
SHOCK ABSORBER
ZX / SCOUT
Brake Arm
Install the brake arm pin.
Connect the brake cable and install the
adjusting nut.
Install the rear wheel. (Ö14-3)
Adjust the rear brake lever free play.
(Ö3-4)
Adjusting Nut
Brake Arm Pin
14-6
ZX / SCOUT
SHOCK ABSORBER
REAR SHOCK ABSORBER
Upper Mount Bolt
REMOVAL
Remove the air cleaner case. (Ö5-2)
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
SHOCK ABSORBER
ZX / SCOUT
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.
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
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: 2.4 3.0kg-m
Install the frame body cover. (Ö12-5)
ZX / SCOUT
Upper Mount Bolt
Lower Mount Bolt
14-9
15. ELECTRICAL EQUIPMENT
ZX / SCOUT
15
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
15
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
CHARGING SYSTEM ........................................................................ 15- 3
BATTERY............................................................................................ 15- 4
IGNITION SYSTEM ........................................................................... 15- 7
STARTING SYSTEM.......................................................................... 15-11
15-0
ZX / SCOUT
SERVICE INFORMATION
• 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 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
SC10AS
Capacity
Voltage
Battery
Charging
current
Spark plug
Standard
0.4A/10H
Quick
4A/0.5H
(NGK)
Spark plug gap
Primary coil
Secondary coil
Ignition coil resistance (with plug cap)
Secondary coil
(without plug cap)
Pulser coil resistance (20 )
Ignition timing
12V3AH
13.0 13.2V
BR8HSA
0.6 0.7mm
0.153 0.187Ω
6.99 10.21KΩ
3.24 3.96KΩ
80 160Ω
15.5°±2°BTDC/2000rpm
TROUBLESHOOTING
CHARGING SYSTEM
No power
• Dead battery
• Disconnected battery cable
• Fuse burned out
• Faulty ignition switch
Intermittent power
• Loose battery cable connection
• Loose charging system connection
• Loose connection or short circuit in ignition system
• Loose connection or short circuit in lighting system
Low power
• Weak battery
• Loose battery connection
• Charging system failure
• Faulty regulator/rectifier
Charging system failure
• Loose, broken or shorted wire or connector
• Faulty A.C. generator
15-1
ZX / SCOUT
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 ignition switch
—Between ignition coil and spark plug
• Faulty ignition coil
• Faulty CDI unit
• Faulty A.C. generator
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
STARTING SYSTEM
Starter motor won‘t turn
• Fuse burned out
• Weak battery
• Faulty starter switch
• Faulty front or rear stop switch
• Faulty starter relay
• Poorly connected, broken or shorted wire
• Faulty starter motor
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
ZX / SCOUT
CHARGING SYSTEM
Dimmer Switch
Headlight Switch
Ignition Switch
Resistor
Regulator/Rectifier
Battery
A.C. Generator
7A
P
15-3
G/B
ZX / SCOUT
Battery Cover
BATTERY
BATTERY REMOVAL
Remove the battery cover.
Disconnect the battery cables .
Remove the bolt and battery bracket.
Remove the battery.
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
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)
Red
Charging current : Standard : 0.4A
Quick : 4A
Charging time : Standard : 5 hours
Quick : 0.5 hour
After charging: Open circuit voltage: 12.8V
min.
Black
15-4
ZX / SCOUT
PERFORMANCE TEST
Warm up the engine.
Remove the floor mat and battery cover.
Stop the engine and open the fuse box.
Disconnect the wire lead from the fuse
terminal. Connect an ammeter between
the wire lead and fuse terminal as shown.
Connect the battery positive (+) terminal to
the voltmeter positive (+) probe and battery
negative (-) terminal to the voltmeter
negative (-) probe.
Start the engine, gradually increase engine
speed to test the output:
Position
RPM
2500
6000
Day
Night
1.3A min.
2.0A min.
1.0A min.
2.0A min.
Charging Limit Voltage: 14.5±0.5V/8000rpm
If the limit voltage is not within the
specified range, check the regulator/
rectifier.
A.C. GENERATOR (CHARGING
COIL) INSPECTION
A.C. Generator Connector
Disconnect the A.C. generator connector.
Measure the resistances between the
charging coil terminals (white–green) and
lighting coil terminals (yellow–green).
Resistances:
Charging coil white–green 0.2 1.2Ω
Lighting coil yellow–green 0.3 1.0Ω
Refer to 7-3 for A.C. generator removal.
15-5
ZX / SCOUT
RESISTOR INSPECTION
Remove the frame front cover. (Ö12-3)
Measure the resistance between the resistor
B pink wire and ground.
Measure the resistance between the resistor
A green/black wire and ground.
Resistances:
Resistor A: 9.9 10.5Ω
Resistor B: 5.6 6.2Ω
REGULATOR/RECTIFIER
INSPECTION
Disconnect the regulator/rectifier wire
coupler and remove the bolt to remove the
regulator/rectifier.
Resister A
Resister B
Bolt
Measure the resistances between the
terminals.
Replace the regulator/rectifier if the
readings are not within the specifications in
the table below.
Coupler
A (Red)
Probe⊕
Probe(-)
A (R)
A (R)
B (W) 3-10KΩ
C (Y)
∞
D (G)
∞
B (W)
∞
C (Y)
∞
∞
∞
∞
Regulator/Rectifier
C (Yellow)
D (G)
∞
∞
33-35K
Ω
33-35K
Ω
B (White)
15-6
ZX / SCOUT
D (Green)
IGNITION SYSTEM
Ignition Coil
Ignition Switch
CDI Unit
Pulser Coil
A.C. Generator (Exciter Coil)
Pulser
Coil
15-7
ZX / SCOUT
IGNITION COIL INSPECTION
Continuity Test
Measure the resistance between the ignition
coil primary coil terminals.
Resistance (20 ): 0.153 0.187Ω
Measure the secondary coil resistance
between the spark plug cap and the primary
coil terminal as Figure A shown.
Resistance (20 ) (with plug cap): 6.99
10.21KΩ
Figure B
Measure the secondary coil resistance
between the ignition coil terminal and the
primary coil terminal as Figure B shown.
Resistance (20 ) (without plug cap): 3.24
3.96KΩ
Figure A
Ignition Coil
Green Black
15-8
ZX / SCOUT
Blue/Yellow
A.C. GENERATOR
Exciter Coil/Pulser Coil Inspection
Disconnect the A.C. generator wire
connector.
Measure the pulser coil resistance between
the blue/yellow wire and ground.
Resistance (20 ): 80 160Ω
15-9
ZX / SCOUT
Blue/
Yellow
∞
3~40 80~120
Green
∞
2~10 10~30
10~30
∞
CDI UNIT INSPECTION
Disconnect the CDI coupler and remove the
CDI unit.
CDI CIRCUIT INSPECTION
Measure the resistance between the
terminals.
Replace the CDI unit if the readings are not
within the specifications in the table below.
Use the x KΩ range for the Sanwa Tester.
Use the x 100Ω range for the Kowa Tester.
Coupler
CDI Unit
Black/
White
Black/
Red
Green
Black/
Yellow
Blue/Yellow
Unit: KΩ
Probe⊕
(-)Probe
Black/ Black/ Black/ Blue/ Green
Yellow Red White Yellow
Black/
Yellow
∞
Black/
Red
∞
Black/
White
∞
∞
∞
∞
∞
1~10
∞
∞
∞
∞
15-10
ZX / SCOUT
Starting System
Starter Button
Starter Button
Ignition Switch
Battery
Starter Relay
Starter
Relay
Starter Button
Starter Morter
15-11
ZX / SCOUT
STARTER RELAY INSPECTION
Disconnect the starter relay coupler and
then remove the starter relay.
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.
Starter Relay
Red
Red/White
Yellow/Red
Green/Yellow
STARTER MOTOR REMOVAL
Disconnect the starter motor cable.
Remove the two bolts attaching the starter
motor and remove the starter motor.
Bolts
removal.
15-12
ZX / SCOUT
Starter Motor
STARTER MOTOR INSPECTION
Connect a battery across the starter motor
and check for its operation.
Starter Motor
Battery (+) Terminal
Battery
15-13
16. INSTRUMENT/SWITCHES/LIGHTS
ZX / SCOUT
16
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
16
__________________________________________________________________________________
INSTRUMENT/SWITCHES/LIGHTS
__________________________________________________________________________________
FUEL UNIT.......................................................................................... 16-2
OIL METER ......................................................................................... 16-3
SWITCHES .......................................................................................... 16-5
STOP SWITCH INSPECTION/HORN ............................................... 16-6
BULB REPLACEMENT ..................................................................... 16-7
INSTRUMENT/HEADLIGHT ............................................................ 16-8
16-0
ZX / SCOUT
SERVICE INFORMATION
• 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
• Weak battery
• Poorly connected wire
• Faulty winker
Light dims
• Faulty ignition coil
• Wire or switch resistance too high
Headlight does not change when dimmer
switch is turn to Hi or Lo
• Faulty or burned bulb
• Faulty dimmer switch
Motor oil indicator light does not come on
(when motor oil is insufficient)
• Fuse burned out
• Dead battery
• Faulty instrument
• Faulty oil meter
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
Fuel gauge pointer fluctuates or swings
• Loose wire connection
• Faulty fuel unit
16-1
ZX / SCOUT
Fuel Unit
FUEL UNIT
REMOVAL
Disconnect the fuel unit wire connectors.
Turn the fuel unit retainer counterclockwise
to remove it.
Remove the fuel unit.
Fuel Unit Wire
Y/W
G
INSPECTION
Remove the fuel unit.
Measure the resistance between the fuel
unit wire terminals with the float at upper
and lower positions.
Wire Terminals
Upper
Lower
G Y/W
G L/W
Y/W L/W
33Ω
566Ω
600Ω
686Ω
53Ω
600Ω
L/W
FUEL GAUGE INSPECTION
Connect the fuel unit wire connectors and
turn the ignition switch “ON”.
Check the fuel gauge needle for correct
indication by moving the fuel unit float up
and down.
Float Position
Needle Position
Upper
“F” (Full)
Lower
“E” (Empty)
16-2
ZX / SCOUT
INSTALLATION
removal.
Retainer
OIL METER
INSPECTION
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 c and d shown in the left
figure.
Wire Terminals
Resistance
Green/Red(+) Black(-)
5 16Ω
Green(-) Black(+)
∞
Oil Meter
G/R
B
Float
c
G G
B
d
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.
Light OFF
Green/Red(+) Black(-)
About 340Ω
4.5±1.0mm
Light ON
16-3
Move the oil meter float up and down to see
if the oil indicator light will go out and
come on.
ZX / SCOUT
Oil Indicator Light
SWITCHES
IGNITION SWITCH INSPECTION
Disconnect the ignition switch wire
couplers and check for continuity between
the wire terminals.
Color Red Black/White Green Black
Symbol BAT1
IG
E
BAT2
LOCK
○
○
OFF
○
○
ON
○
○
Ignition Switch Coupler
Bolts
IGNITION SWITCH REPLACEMENT
Disconnect the ignition switch wire
couplers.
Remove the two mounting bolts and
remove the ignition switch.
removal.
16-4
HEADLIGHT SWITCH INSPECTION
Remove the handlebar rear cover. (Ö12-3)
Disconnect the headlight switch wire
coupler and check for continuity between
wire terminals.
Color
Blue/White Yellow Brown Pink
Symbol
HL
CL
○
○
○
○
OFF
P
H
TL
L/W
Y
Brown/White
RE
○
○
○
○
P
Br
Br/W
Headlight Switch
L
DIMMER SWITCH INSPECTION
Check for continuity between wire
terminals.
Color Blue/White Blue
Symbol
HL
HI
HI
○
○
LO
○
PASSING
○
ZX / SCOUT
W
White Black
LO PASS
○
B
○
L/W
Dimmer Switch
O
TURN SIGNAL SWITCH
INSPECTION
Check for continuity between the wire
terminals.
Color
Symbol
R
L
Light Blue Orange
R
L
○
○
Gray
WR
○
○
Gr
Turn Signal Switch
16-5
SB
STARTER SWITCH INSPECTION
terminals.
Push the starter button when measuring.
Color
Symbol
FREE
PUSH
Yellow/Red
ST
Green
E
○
○
ZX / SCOUT
Y/R
G
Starter Switch
HORN SWITCH INSPECTION
terminals.
Push the horn button when measuring.
Color
Symbol
FREE
PUSH
Light Green
HO
Black
BAT2
○
○
Lg
B
Horn Switch
STOP SWITCH INSPECTION
Remove the handlebar front cover. (Ö12-3)
Disconnect the front and rear stop switch
wire couplers.
Check for continuity between the wire
terminals when the front/rear brake lever is
applied.
16-6
HORN INSPECTION
Remove the frame front cover. (Ö12-3)
Disconnect the horn wire couplers. The
horn is normal if it sounds when a 12V
battery is connected across the horn wire
terminals.
ZX / SCOUT
Horn
Battery
FRONT TURN SIGNAL LIGHT
REPLACEMENT
Remove the turn signal light shell and the
bulb.
Replace with new ones.
Turn Signal Light Bulb
TAILLIGHT/STOPLIGHT/REAR TURN
SIGNAL LIGHT BULB REPLACEMENT
Taillight Shell Removal:
Remove two screws attaching the taillight
shell.
Remove the taillight shell and stop light
bulb.
Remove the rear turn signal light bulbs.
removal.
Taillight Shell
Screws
16-7
ZX / SCOUT
INSTRUMENT
Instrument Bulbs Replacement
Remove the handlebar rear cover. (Ö12-3)
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.
removal.
Bulb Sockets
HEADLIGHT
REMOVAL/BULB REPLACEMENT
Remove the handlebar front cover. (Ö12-3)
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
for replacement.
removal.
16-8
17. EVAPORATIVE/EXHAUST EMISSION
CONTROL SYSTEM
ZX / SCOUT
17
17
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
EVAPORATIVE/EXHAUST EMISSION
CONTROL SYSTEM
__________________________________________________________________________________
EXHAUST EMISSION CONTROL SYSTEM................................... 17-1
EXHAUST MUFFLER ........................................................................ 17-2
EXHAUST EMISSION RELATED SYSTEM INSPECTION ........... 17-3
17-0
CONTROL SYSTEM
ZX / SCOUT
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system adopted by this model is an oxidizing catalytic converter
which is located in the middle of the exhaust muffler to reduce pollutants in the exhaust
emission.
Exhaust Muffler Diagram
Catalytic Converter
FUNCTION
Item
Oxidizing
Catalytic
Converter
Purpose
Function
Reduce the concentration of
HC and CO in the exhaust
emission.
The precious metal in the oxidizing catalytic
converter is used to oxidize HC and CO in
the exhaust emission into CO2 and H2O to
avoid air pollution.
TROUBLESHOOTING
Lack of power and high CO & 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
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
CONTROL SYSTEM
ZX / SCOUT
EXHAUST MUFFLER
REMOVAL
nuts and two exhaust muffler lock bolts.
• The temperature of exhaust muffler is
very high. Be careful to avoid burns
during working.
Exhaust Muffler
Lock Bolts
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.
• A large amount of unburned mixture flowing
into the high-heat catalytic converter will burn
again and cause damage to the converter due to
overheat. Pay attention to the following.
• Use 92# or 95# nonleaded gasoline only.
(Leaded gasoline will cause catalytic converter
failure.)
• 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.
Exhaust Muffler Joint Lock Nut
17-2
CONTROL SYSTEM
ZX 50
ZX 50
EXHAUST EMISSION RELATED SYSTEM INSPECTION
Clean or replace the air cleaner.
Clean and adjust the carburetor.
Inspect the auto bystarter system.
Clean and inspect the spark plug.
Inspect the ignition system.
EXHAUST EMISSION TEST AND ADJUSTMENT
1. Start the engine and warm up for several minutes. (Engine surface temperature 50 60 )
2. Adjust the idle speed to:: 2000±100rpm +100
−50
3. Connect the emission tester sampling pipe to the exhaust muffler.
Standard:
CO: 3±0.5%
HC: 7000PPM max.
4. If CO or HC exceeds the specified values, adjust the carburetor air screw (A.S.) until CO and HC
are within the specified standard values.
A.S. Opening: 1¼±½ turns
5. If the adjustment of carburetor makes no difference, inspect exhaust emission related system.
17-3
K YMCO T ECHNICAL I NFORMATION
Model ALL MODEL (For EURO 2)
Subject KYMCO Clean Air System (For EURO 2)
Date: 8.JAN.04
NO.: KTI-04002
KYMCO Clean Air System (For EURO 2)
The KYMCO Clean Air System is a secondary air suction system that helps the exhaust
gases to burn more completely. When the spent fuel charge is released into the exhaust system,
it is still hot enough to burn. The system allows extra air into the exhaust system so that the
spent fuel charge can continue to burn. This continued burning action tends to burn up a great
deal of the normally unburned gases, as well as changing a significant portion of the poisonous
carbon monoxide into harmless carbon dioxide.
Secondary Air Suction System Diagram (4-stroke)
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K YMCO T ECHNICAL I NFORMATION
Model ALL MODEL (For EURO 2)
Subject KYMCO Clean Air System (For EURO 2)
Date: 8.JAN.04
NO.: KTI-04002
Secondary Air Suction System Diagram (2-stroke)
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