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KYMCO Scout 50 User Manual

KYMCO Scout 50
188 pages
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ZX / SCOUT
50
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

Table of Contents

Questions and Answers:

KYMCO Scout 50 Specifications

General IconGeneral
Engine Stroke4-Stroke
Displacement49 cc
Compression Ratio10.0:1
Fuel SystemCarburetor
Front BrakeDisc
Rear BrakeDrum
Tires Front120/70-12
Tires Rear130/70-12
Fuel Capacity6.5 liters
IgnitionCDI
Front SuspensionTelescopic Fork
Max Power2.4 kW (3.2 hp) @ 7500 rpm
TransmissionAutomatic
Starting SystemElectric
Wheelbase1320 mm

Summary

PREFACE

1. SPECIFICATIONS

2. GENERAL INFORMATION

SERVICE PRECAUTIONS

Important safety and operational guidelines for servicing the motorcycle.

SERVICE INFORMATION

Technical data and specifications for engine, carburetor, and frame components.

TORQUE VALUES

Specified torque settings for engine and frame fasteners during maintenance.

SPECIAL TOOLS

List of specialized tools required for specific repair and maintenance tasks.

TROUBLESHOOTING

Diagnostic guides for common engine starting and running issues.

3. INSPECTION/ADJUSTMENT

INSPECTION AND MAINTENANCE SCHEDULE

Schedule for regular checks, maintenance, and part replacement based on usage.

BRAKE SYSTEM

Procedures for inspecting and maintaining the front and rear brake systems.

ENGINE

Procedures for checking and adjusting engine idle speed and air cleaner.

4. LUBRICATION SYSTEM

SERVICE INFORMATION

General instructions and recommended lubricants for the oil pump system.

TROUBLESHOOTING

Diagnosis for issues like excessive smoke, engine overheating, and seized pistons.

OIL PUMP REMOVAL

Step-by-step guide for removing the engine's oil pump assembly.

5. ENGINE REMOVAL/INSTALLATION

SERVICE INFORMATION

General instructions and torque values for engine servicing.

ENGINE REMOVAL

Detailed steps for removing the engine from the motorcycle chassis.

ENGINE INSTALLATION

Procedures for reinstalling the engine and post-installation checks.

6. CYLINDER HEAD/CYLINDER/PISTON

SERVICE INFORMATION

General instructions and specifications for cylinder head, cylinder, and piston.

TROUBLESHOOTING

Diagnostic tips for low compression, overheating, or knocking issues.

CYLINDER HEAD

Procedures for removing, inspecting, and installing the cylinder head.

7. A.C. GENERATOR

SERVICE INFORMATION

General instructions and torque values for A.C. generator maintenance.

A.C. GENERATOR REMOVAL

Step-by-step guide for removing the A.C. generator components.

8. KICK STARTER/DRIVE PULLEY/CLUTCH/DRIVEN PULLEY

SERVICE INFORMATION

General instructions, specifications, and torque values for the drive system.

TROUBLESHOOTING

Diagnostic tips for engine starting issues and poor performance.

KICK STARTER

Removal, inspection, and installation of the kick starter mechanism.

DRIVE BELT

Procedures for inspecting and replacing the drive belt.

9. FINAL REDUCTION

SERVICE INFORMATION

Specified oil and troubleshooting for the final reduction gears.

FINAL REDUCTION DISASSEMBLY

Steps for disassembling the final reduction gear assembly.

10. CRANKCASE/CRANKSHAFT

SERVICE INFORMATION

General instructions, specifications, and tools for crankshaft servicing.

CRANKCASE SEPARATION

Steps for separating the crankcase halves.

CRANKSHAFT INSPECTION

Measuring clearances and checking crankshaft runout.

11. CARBURETOR

TROUBLESHOOTING

Troubleshooting common carburetor issues like poor idling or starting.

FLOAT LEVEL INSPECTION

Measuring and adjusting the float level.

AIR SCREW ADJUSTMENT

Adjusting the air screw for optimal idle speed and engine performance.

12. FRAME COVERS

SERVICE INFORMATION

Precautions for removing frame covers without damaging joint claws.

FRAME COVERS REMOVAL

Instructions for removing handlebar, front, lower, and bottom covers.

13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK

FRONT BRAKE (DISK BRAKE)

Brake fluid replacement, bleeding, and caliper maintenance.

FRONT SHOCK ABSORBER

Disassembly, assembly, and installation of front shock absorbers.

FRONT FORK

Removal, inspection, and installation of the front fork and steering bearings.

14. REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER

REAR WHEEL

Removal, inspection, and installation of the rear wheel.

REAR BRAKE

Disassembly, assembly, and inspection of the rear brake system.

15. ELECTRICAL EQUIPMENT

CHARGING SYSTEM

Inspection of the A.C. generator and regulator/rectifier.

BATTERY

Battery removal, charging, and inspection procedures.

IGNITION SYSTEM

Inspection and testing of ignition coil, CDI unit, and pulser coil.

STARTING SYSTEM

Inspection and removal of starter motor and relay.

16. INSTRUMENT/SWITCHES/LIGHTS

FUEL UNIT

Removal, inspection, and installation of the fuel unit and gauge.

OIL METER

Inspection and operation check of the oil meter and indicator light.

SWITCHES

Inspection and replacement of ignition, dimmer, and turn signal switches.

STOP SWITCH INSPECTION/HORN

Inspection of stop switches and horn function.

17. EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM

EXHAUST EMISSION CONTROL SYSTEM

Explanation of the oxidizing catalytic converter and its function.

EXHAUST MUFFLER

Removal, inspection, and installation of the exhaust muffler.

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