KYMCO ZX/SCOUT 50 User Manual

2. GENERAL INFORMATION
2-0
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

KYMCO ZX/SCOUT 50 Specifications

General

Brand	KYMCO
Model	ZX/SCOUT 50
Category	Scooter
Language	English

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

Final Reduction Disassembly and Inspection

Bearing Replacement Procedures

Final Reduction Assembly and Oil Filling

10. Crankcase/Crankshaft

Crankcase Separation and Crankshaft Removal

Crankshaft Inspection and Installation

Crankcase Assembly Procedures

11. Carburetor

Throttle Valve and Auto Bystarter Service Procedures

Float Chamber Service Procedures

Carburetor Installation and Air Screw Adjustment

Reed Valve Service Procedures

Fuel Tank Removal Procedures

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

Steering Handlebar Service Procedures

Front Wheel Service Procedures

Front Brake Service Procedures

Front Shock Absorber Service Procedures

Front Fork Service Procedures

14. Rear Wheel/Rear Brake/Rear Shock Absorber

Rear Wheel Service Procedures

Rear Brake Service Procedures

Rear Shock Absorber Service Procedures

15. Electrical Equipment

Battery Service Procedures

A.C. Generator and Resistor Inspections

Ignition System Component Inspections