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KYMCO ZX/SCOUT 50 User Manual

KYMCO ZX/SCOUT 50
191 pages
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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

Table of Contents

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KYMCO ZX/SCOUT 50 Specifications

General IconGeneral
Fuel SystemCarburetor
Front SuspensionTelescopic fork
Engine TypeSingle cylinder, 2-stroke
Cooling SystemAir cooled
TransmissionCVT
Starting SystemElectric & Kick
Brakes FrontDisc brake
Brakes RearDrum

Summary

2. General Information

Service Precautions and Safety Guidelines

Lists critical precautions for safe and effective motorcycle servicing.

Troubleshooting Guide

Offers diagnostic steps for common engine starting, performance, and operational issues.

3. Inspection/Adjustment

Inspection and Maintenance Schedule

Provides a comprehensive schedule for routine inspections and maintenance tasks.

Ignition System and Engine Adjustments

Covers spark plug, ignition timing, idle speed, and air cleaner inspections.

Lubrication System and Oil Pump Checks

Details oil filter cleaning, cylinder compression, and oil pump condition checks.

4. Lubrication System

Oil Pump Service Procedures

Details the procedures for removing, inspecting, installing, and bleeding the oil pump.

Oil Tank Removal Procedures

Details the steps for removing the oil tank.

5. Engine Removal/Installation

Engine Removal Procedures

Details the step-by-step process for removing the engine from the frame.

Engine Installation Procedures

Details the steps for installing the engine and post-installation checks.

6. Cylinder Head/Cylinder/Piston

Service Information, Specifications, and Troubleshooting

Covers general instructions, specifications, and torque values for cylinder head, cylinder, and piston service.

Cylinder Head Service Procedures

Details removing the cylinder head, decarbonizing, and checking for warpage.

Cylinder and Piston Service Procedures

Details removing the cylinder and piston, and inspecting them for wear and damage.

7. A.C. Generator

A.C. Generator Removal Procedures

Details removing the fan cover, cooling fan, flywheel, and pulser coil.

A.C. Generator Installation Procedures

Details installing the flywheel, checking ignition timing, and connecting wires.

8. Kick Starter/Drive Pulley/Clutch/Driven Pulley

Kick Starter Service Procedures

Details kick starter removal, inspection, and installation steps.

Drive Belt Service Procedures

Covers drive belt inspection, replacement, and installation.

Drive Pulley Service Procedures

Details drive pulley removal, disassembly, inspection, and installation.

Starter Pinion Service Procedures

Covers starter pinion removal, inspection, and installation.

Clutch/Driven Pulley Service Procedures

Details clutch/driven pulley removal, disassembly, inspection, and assembly.

9. Final Reduction

10. Crankcase/Crankshaft

11. Carburetor

13. Steering Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Front Fork

14. Rear Wheel/Rear Brake/Rear Shock Absorber

15. Electrical Equipment

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