GENERAL INFORMATION - Sell Files and Downloads ... INFORMATION 2-8 ZX / SCOUT 50 TORQUE VALUES...

2. GENERAL INFORMATION

2-0

ZX / SCOUT 50

1 __________________________________________________________________________________

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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


2-1

ZX / SCOUT 50

ENGINE SERIAL NUMBER/IDENTIFICATION

Location of Engine Serial Number


2-2

ZX / SCOUT 50

SERVICE PRECAUTIONS

nMake sure to install new gaskets, O-rings,circlips, cotter pins, etc. when reassembling.

nWhen tightening bolts or nuts, begin withlarger-diameter to smaller ones at severaltimes, and tighten to the specified torquediagonally.

n Use genuine parts and lubricants.

nWhen servicing the motorcycle, be sure touse special tools for removal andinstallation.

n After disassembly, clean removed parts.Lubricate sliding surfaces with engine oilbefore reassembly.

n Apply or add designated greases andlubricants to the specified lubricationpoints.

n After reassembly, check all parts forproper tightening and operation.

nWhen two persons work together, payattention to the mutual working safety.

n Disconnect the battery negative (-) terminalbefore operation.nWhen using a spanner or other tools, make

sure not to damage the motorcycle surface.

n After operation, check all connectingpoints, fasteners, and lines for properconnection and installation.nWhen connecting the battery, the positive

(+) terminal must be connected first.n After connection, apply grease to the

battery terminals.n Terminal caps shall be installed securely.


2-3

ZX / SCOUT 50

n If the fuse is burned out, find the cause andrepair it. Replace it with a new oneaccording to the specified capacity.

n After operation, terminal caps shall beinstalled securely.

nWhen taking out the connector, the lock onthe connector shall be released beforeoperation.

n Hold the connector body when connectingor disconnecting it.n Do not pull the connector wire.

n Check if any connector terminal is bending,protruding or loose.

n The connector shall be insertedcompletely.n If the double connector has a lock, lock

it at the correct position.n Check if there is any loose wire.

n Before connecting a terminal, check fordamaged terminal cover or loose negativeterminal.

n Check the double connector cover forproper coverage and installation.

n Insert the terminal completely.n Check the terminal cover for proper

coverage.n Do not make the terminal cover opening

face up.

n Secure wire harnesses to the frame withtheir respective wire bands at thedesignated locations.Tighten the bands so that only theinsulated surfaces contact the wireharnesses.

Easy confirm


2-4

ZX / SCOUT 50

n After clamping, check each wire to makesure it is secure.

n Do not squeeze wires against the weld orits clamp.

n After clamping, check each harness to makesure that it is not interfering with anymoving or sliding parts.

nWhen fixing the wire harnesses, do notmake it contact the parts which willgenerate high heat.

n Route wire harnesses to avoid sharp edgesor corners. Avoid the projected ends ofbolts and screws.n Route wire harnesses passing through the

side of bolts and screws. Avoid theprojected ends of bolts and screws.

n Route harnesses so they are neitherpulled tight nor have excessive slack.

n Protect wires and harnesses with electricaltape or tube if they contact a sharp edge orcorner.

nWhen rubber protecting cover is used toprotect the wire harnesses, it shall beinstalled securely.

n Do not break the sheath of wire.n If a wire or harness is with a broken sheath,

repair by wrapping it with protective tapeor replace it.

nWhen installing other parts, do not press orsqueeze the wires.

Don’t touch


2-5

ZX / SCOUT 50

n After routing, check that the wire harnessesare not twisted or kinked.

nWire harnesses routed along with handlebarshould not be pulled tight, have excessiveslack or interfere with adjacent orsurrounding parts in all steering positions.

nWhen a testing device is used, make sure tounderstand the operating methodsthoroughly and operate according to theoperating instructions.

n Be careful not to drop any parts.

nWhen rust is found on a terminal, removethe rust with sand paper or equivalentbefore connecting.

n Symbols:The following symbols represent theservicing methods and cautions included inthis service manual.

: Apply engine oil to thespecified points. (Usedesignated engine oil forlubrication.)

: Apply grease for lubrication.

: Use special tool.

: Caution

: Warning

(!12-3) : Refer to page 12-3.

Engine Oil

Grease

Special

＊

Remove the rest


2-6

ZX / SCOUT 50

SERVICE INFORMATION

ENGINE Standard (mm) Service Limit (mm)

Item SC10AS SC10AS

Cylinder head warpage æ 0.10

Piston O.D.(5mm from bottom of pistonskirt)

38.955_ 38.970 38.90

Cylinder-to- piston clearance 0.10

Piston pin hole I.D. 12.002_ 12.008 12.03

Piston pin O.D. 11.994_ 12.0 11.98

Piston-to-piston pin clearance ¨ ¨

Piston ring end gap (top/second) 0.10_ 0.25 0.40

Connecting rod small end I.D. 17.005_ 17.017 17.03

Cylinder bore 39.0_ 39.025 39.05

Drive belt width 18 17

Drive pulley collar O.D. 20.01_ 20.025 ¨

Movable drive face ID. 20.035_ 20.085 19.97

Weight roller O.D. 13.0 12.4

Clutch outer I.D. 107_ 107.2 107.5

Driven face spring free length 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 æ ¨

CARBURETOR SC10AS

Venturi dia. 14mm

Identification number 014A

Float level 5.0mm

Main jet #80

Slow jet #35

Air screw opening 1 ±_

Idle speed 2100±100rpm

Throttle grip free play 2_ 6mm

Jet needle clip notch 1st notch


2-7

ZX / SCOUT 50

FRAME Standard (mm) Service Limit (mm)

Item SC10AS SC10AS

Axle shaft runout æ 0.2

RadialFront wheel rim runout

Axial

Front shock absorber spring free length 200.0 182.8

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 æ 0.30

Rear shock absorber spring free length 235.7 218.7

ELECTRICAL EQUIPMENT SC10AS

Capacity 12V3AH

Voltage 13.0_ 13.2V

Charging Standard 0.4A/5HBattery

current Quick 4A/0.5H

Spark plug (NGK) BR8HSA

Spark plug gap 0.6_ 0.7mm

Primary coil 0.153_ 0.187WSecondary coil(with plug cap) 6.99_ 10.21KWIgnition coil resistanceSecondary coil(without plug cap) 3.24_ 3.96KW

Pulser coil resistance (20℃ ) 80_ 160W

Ignition timing 15.5°±2°BTDC/2000rpm


2-8

ZX / SCOUT 50

TORQUE VALUES

ENGINE

Item Thread dia. (mm) Torque (kg-m) Remarks

Cylinder head boltClutch drive plate nutClutch outer nutDrive face nutOil check boltEngine mounting boltEngine hanger bracket boltExhaust muffler joint lock nutExhaust muffler lock boltSpark plug

BF7x11510

NH10NH12

10BF10x95BF10x50NC6mmBF8x35

1.5_ 1.73.5_ 4.03.5_ 4.55.0_ 6.01.0_ 1.54.5_ 5.53.5_ 4.51.0_ 1.43.0_ 3.61.1_ 1.7

(cold)

(cold)

FRAME

Item Thread dia. (mm) Torque (kg-m) Remarks

Handlebar lock nutSteering stem lock nutSteering top cone raceFront axle nutRear axle nutRear brake arm boltFront shock absorber: upper mount bolt lower mount bolt hex boltFront damper nutFront pivot arm boltRear shock absorber: upper mount bolt lower mount bolt lower joint nut

1025.425.41216

8

8

1088

4.5_ 5.08.0_ 12.00.5_ 1.35.0_ 7.0

11.0_ 13.0

3.33.3

1.5_ 3.01.5_ 3.0

3.5_ 4.52.4_ 3.01.5_ 2.5

Flange bolt/U-nut

Flange U-nutFlange U-nutFlange nut

Flange bolt/U-nutCross headApply locking agent

Flange screw/U-nut

Flange nut

Torque specifications listed above are for important fasteners. Others should be tightened tostandard torque values below.

STANDARD TORQUE VALUES SH bolt: 8mm Flange 6mm bolt

Item Torque (kg-m) Item Torque (kg-m)

5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm bolt, nut

0.45_ 0.60.8_ 1.21.8_ 2.53.0_ 4.05.0_ 6.0

5mm screw6mm screw, SH bolt6mm flange bolt, nut8mm flange bolt, nut10mm flange bolt, nut

0.35_ 0.50.7_ 1.11.0_ 1.42.4_ 3.03.5_ 4.5


2-9

ZX / SCOUT 50

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

Bearing remover set, 15mm(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 & crankcaseassembly

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

Bearing outer driver, 32x35mm E014 Drive shaft bearing installationFinal shaft bearing installation

Bearing outer driver, 37x40mm E014Drive shaft bearing installation Final shaftbearing installation Crankshaft bearinginstallation

Universal bearing puller E030 Crankshaft bearing removal


2-10

ZX / SCOUT 50

LUBRICATION POINTS

ENGINE

NO. Lubrication Points Lubricant Remarks1 Crankcase sliding & movable parts JASO-FC or API-TC

2 Cylinder movable parts JASO-FC or API-TC

3 Transmission gear (final gear) SAE-90#

4 Kick starter spindle bushing Grease

5 Drive pulley movable parts Grease

6 Starter pinion movable parts Grease

FRAMEApply clean engine oil or grease to cables and movable parts not specified. This will avoidabnormal noise and rise the durability of the motorcycle.

Front/Rear Brake Lever

Seat Lock

Rear Wheel Bearing

Throttle Cable

Main Stand Pivot

Grease

Engine OilGrease

Engine Oil

Speedometer Gear/Brake Cam/FrontShock AbsorberLower MountBushings/Pivot

Grease

Grease

Grease

GreaseEngine Oil

Rear Brake Cable

Brake Cam/Anchor Pin


2-11

ZX / SCOUT 50SC10AS WIRING DIAGRAM


2-12

ZX / SCOUT 50

CABLE & HARNESS ROUTING

Front Brake Reservoir

Rear Brake CableThrottle Cable

Ignition Switch

Regulator/Rectifier

Front Brake Fluid Tube

Resistor

Front Stop Switch WireRear Stop Switch Wire

Speedometer Cable

Speedometer Cable


Horn


2-13

ZX / SCOUT 50

Wire Harness

Rear Brake Cable

Throttle Cable


Speedometer Cable

Speedometer Cable



2-14

ZX / SCOUT 50

Ignition Coil

Fuel Unit

Fuel Filter

Oil Tank Cap

Starter Relay

CDI Unit

BatteryWire Harness

Ignition Coil

Oil Tube


2-15

ZX / SCOUT 50

Vacuum Tee

Oil Pump

Ignition Coil

Oil Tube

Fuel UnitFuel Tank Cap


2-16

ZX / SCOUT 50TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

Å Empty fuel tankÇ Clogged float valveÉ Clogged fuel filterÑ Faulty auto fuel valve

Å Faulty spark plugÇ Fouled spark plugÉ Faulty CDI unitÑ Faulty A.C. generatorÖ Broken or shorted

ignition coilÜ Broken or shorted

exciter coiláFaulty ignition switch

Å Burned or worncylinder pistonÇ Faulty reed valveÉ Blown cylinder head

gasketÑ Leaking crankcaseÖ Faulty crankcase oil

seal

Å Incorrectly adjusted idlespeedÇ Air leaking through

intake pipeÉ Incorrect ignition

timing

Å Flooded carburetorÇ Throttle valve

excessively open

Å Faulty auto bystarter

Check if fuel reachescarburetor byloosening drain screw.

Remove spark plugand install it intospark plug cap to testspark by connecting itto engine ground.

Inspection/Adjustment Symptom Probable Cause

Fuel reaches carburetor

Spark jumps

Dry spark plug

Not clogged

Normal compression

Engine does not fire

Fuel does not reach carburetor

Weak or no spark

Wet spark plug

Clogged

Low or no compression

Engine fires but does not start

Test cylindercompression.

Remove spark plug andinspect again.

Wait for 30 minutesand then remove thecarbu-retor auto chokecircuit hose and blowthe hose with mouth.

Start engine by follow-ing normal startingprocedure.


2-17

ZX / SCOUT 50ENGINE STOPS IMMEDIATELY AFTER IT STARTS

Å Empty fuel tankÇ Clogged float valveÉ Clogged fuel filterÑ Faulty auto fuel valve

Å Fouled spark plugÇ Incorrect heat range

plug

Å Fouled spark plugÇ Faulty CDI unitÉ Faulty A.C. generatorÑ Faulty ignition coilÖ Broken or shorted high

tension wireÜ Faulty ignition switch

Å Worn cylinder andpiston ringsÇ Blown cylinder head

gasketÉ Flaws in cylinder headÑ Faulty reed valveÖ Seized piston

Å Clogged carburetor jets

Å Faulty CDI unit or A.C.generatorÇ A.C.G. flywheel not

aligned

Å Mixture too rich (turnscrew out)Ç Mixture too lean (turn

screw in)

Check if fuel reachescarburetor byloosening drain screw.


Fuel reaches carburetor

Good spark


Correct timing

Correctly adjusted

Plug not fouled ordiscolored

Normal compression

Not Clogged

Fuel does not reach carburetor

Weak or inter- mittent spark

Incorrect timing

Incorrectly adjusted

Plug fouled or discolored

Abnormal compression

Clogged

Test cylindercompression (using acompression gauge).

Check carburetor forclogging.

Check ignition timing.

Check carburetor airscrew adjustment.



2-18

ZX / SCOUT 50

Å Carburetor not securelytightenedÇ Faulty intake manifold

gasketÉ Deformed or broken

carburetor O-ring

Å Broken cableÇ Dirty auto bystarterÉ Faulty auto bystarter



No air leak

Not clogged

Clogged

Air leaks

Clogged

Not Clogged

Check carburetorgasket for air leaks.

Connect auto bystarterwire to battery. Waitfor 5 minutes, thenconnect a hose to fuelenriching circuit andthen blow the hosewith mouth.

Remove auto bystarterconnecting wire andcheck if bypass fuelline is clogged.


2-19

ZX / SCOUT 50

ENGINE LACKS POWER

Å Clogged air cleanerÇ Clogged fuel filterÉ Clogged exhaust

mufflerÑ Faulty auto bystarter

Å Faulty CDI unitÇ Faulty A.C. generator

Å Worn cylinder andpiston ringsÇ Blown cylinder head

gasketÉ Faulty reed valve

Å Clogged carburetor jets

Å Fouled spark plugÇ Incorrect heat range

plug

Å Mixture too leanÇ Poor quality fuelÉ Excessive carbon build-

up in combustion chamberÑ Ignition timing too

early

Å Excessive carbon build-up in combustion chamberÇ Poor quality fuelÉ Clutch slippingÑ Mixture too lean


Engine speed increases

Engine overheats

Correct timing

Engine does not knock

Plug not fouled ordiscolored

Normal compression

Not Clogged

Engine speed does not increase sufficiently

Engine does not overheats

Incorrect timing

Engine knocks

Plug fouled or discolored

Abnormal compression

Clogged

Start engine andaccelerate lightly forobservation.

Check ignition timing(using a timing light).

Rapidly accelerate orrun at high speed

Test cylindercompression (using acompression gauge)

Check carburetor forclogging

Remove spark plugandinspect

Check if engineoverheats


2-20

ZX / SCOUT 50

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Å Faulty CDI unitÇ Faulty A.C. generator

Å Mixture too rich (turnscrew out)Ç Mixture too lean (turn

screw in)

Å Carburetor not securelytightenedÇ Faulty intake manifold

gasketÉ Deformed carburetor

O-ring

Å Faulty or fouled sparkplugÇ Faulty CDI unitÉ Faulty A.C. generatorÑ Faulty ignition coilÖ Broken or shorted high

tension wireÜ Faulty ignition switch

Å Broken auto bystarterwire

Ç Faulty auto bystarter


Clogged Not clogged





Check carburetorgasket for air leaks.

Check carburetor airscrew adjustment.

Correct timing Incorrect timing

Correctly adjusted Incorrectly adjusted

No air leak Air leaks

Good spark Weak or inter- mittent spark

Not clogged Clogged


2-21

ZX / SCOUT 50

POOR PERFORMANCE (AT HIGH SPEED)

Å Faulty CDI unitÇ Loose A.C.G. statorÉ Faulty A.C. generator

Å Empty fuel tankÇ Clogged fuel tube or

filterÉ Clogged charcoal

canister

Å Clean and unclog

Å Broken auto bystarterwireÇ Faulty auto bystarter



Clogged Not clogged




Check carburetor jetsfor clogging.

Check auto fuel valvefor fuel supply.

Correct timing Incorrect timing

Fuel flows freely Fuel flowrestricted

Not clogged Clogged

Not clogged Clogged


2-22

ZX / SCOUT 50CLUTCH, DRIVE AND DRIVEN PULLEYS

Å Worn or slipping drive beltÇ Broken ramp plateÉ Broken driven face springÑ Separated clutch liningÖ Damaged driven pulley shaft

splinesÜ Damaged final geará Seized final gear

Å Broken shoe springÇ Clutch outer and clutch weight

stuckÉSeized pivot

Å Worn or slipping drive beltÇ Worn weight rollersÉ Seized drive pulley bearingsÑ Weak driven face springÖ Worn or seized driven pulley

bearings

Å Worn or slipping drive beltÇ Worn weight rollersÉ Worn or seized driven pulley

bearings

Å Oil or grease fouled drive beltÇ Worn drive beltÉ Weak driven face springÑ Worn or seized driven pulley

bearingsSTEERING HANDLEBAR DOES NOT TRACK STRAIGHT

(Front and rear tire pressures are normal)

Å Steering stem nut too tightÇ Broken steering steel balls

Å Excessive wheel bearing playÇ Bent rimÉ Loose axle nut

Å Misaligned front and rear wheelsÇ Bent front fork

Engine starts butmotor-cycle does notmove

Engine lacks power atstart of a grade (poorslope performance)

Steering is heavy

Front or rear wheel iswobbling

Symptom

Symptom

Probable Cause

Probable Cause

Engine lacks power athigh speed

There is abnormalnoiseor smell while running

Motorcycle creeps orengine starts but soonstops or seems to rushout (Rear wheelrotates when engineidles)

Steering handlebar pullsto one side


2-23

ZX / SCOUT 50

POOR SUSPENSION PERFORMANCE

(Front and rear tire pressures are normal)

Å Weak shock springÇ Excessive loadÉ Shock damper oil leaking

Å Bent fork tube or shock rodÇ Fork slider and tube binding

Å Fork tube and spring bindingÇ Fork slider and tube binding

POOR BRAKE PERFORMANCE

(Adjust brake according to standards)

Å Worn brake liningsÇ Worn brake cam contacting area

onbrake shoesÉ Worn brake camÑ Worn brake drum

Å Worn brake liningsÇ Foreign matter on brake liningsÉ Rough brake drum contacting area

Å Sluggish or elongated brake cablesÇ Brake shoes improperly contact

brake drumÉ Water and mud in brake systemÑ Oil or grease on brake linings

Å Faulty brake master cylinderÇ Faulty brake caliperÉ Oil or grease on brake diskÑ Deformed brake diskÖ Leaking brake fluid tube

Suspension is too soft

Brake squeaks

Symptom

Symptom

Probable Cause

Probable Cause

Suspension is too hard

Suspension is noisy

Brake performance ispoor

Index mark on brakepanel aligns with wearindicator arrow

ExpandingBrake

HydraulicBrake


2-24

ZX / SCOUT 50

Faulty

OIL METER

1. Motor oil indicator light does not come on when there is no motor oil (Ignition switch ON)

Å Burned out fuseÇ Weak or dead batteryÉ Faulty ignition switchÑ Loose or disconnected

connectorÖ Broken wire harness

ÅBurned out bulb

Å Loose wire connectorÇ Broken wire harnessÉ Incorrectly connected

wire

Å Faulty floatÇ Broken or shorted wire

inmeter

2. Motor oil is sufficient but the indicator light remains on (Ignition switch ON)

Å Loose or disconnectedconnectorÇ Broken wire harnessÉ Incorrectly connected

wire

Å Faulty floatÇ Broken or shorted wire

in meter

Å Damaged oil tankÇ Foreign matters in oil

tank

Inspection/Adjustment Symptom

Inspection/Adjustment

Probable Cause

Symptom Probable Cause

Signals operate properly

Signals dim, remainon or don‘toperate

Bulb lights Bulb does not light

Good Faulty

Remove oil meter andcheck operation ofindicator light bymoving float

Check connectors forproper connection.

Good

Good Faulty

Remove oil meter andcheck operation ofindicator light bymoving float

Check connectors forproper operation.

Connect indicatorlight bulb to batteryfor bulb inspection.

Check battery circuitby operating turnsignals.

Good Faulty

Float up = Light offFloat down = Light on

Float up = Light offFloat down = Light on


2-25

ZX / SCOUT 50

FUEL GAUGE1. Pointer does not register correctly (Ignition switch ON)



Å Faulty float

Å Broken or shorted fuelunit wire

Å Loose or disconnectedconnectorÇ Incorrectly connected

connectorÅ Broken or shorted wire

in fuel gauge2. Pointer fluctuates or swings (Ignition switch ON)



Å Poor contact in fuelunit

Å Insufficient damping oilin fuel gauge

Å Loose or disconnectedconnectorÅ Broken or shorted wire

in fuel gauge



Symptom

Symptom





Pointer does not move

Pointer does not move

Good

Good

Pointer moves

Pointer moves

Pointer moves

Pointer does notmove in accord-ance with float

Faulty

Faulty

Pointer does notmove

Pointer moves inaccordance withfloat

Probable Cause

Probable Cause

Remove fuel unit andcheck operation ofpointer by movingfloat up and down.

Check battery circuitby operating turnsignals.

Check operation ofpointer by openingand shorting fuel unitterminal on wireharness side.


Remove fuel unit andcheck operation ofpointer by movingfloat up and down.

Check battery circuitby operating turnsignals and horn.

Move float up anddown rapidly (1 round/sec.) to check theoperation of pointer.



2-26

ZX / SCOUT 50STARTER MOTOR1. Starter motor won‘t turn

Å Burned out fuseÇ Weak or dead batteryÉ Faulty stop switchÑ Loose or disconnected

connectorÖ Broken or shorted

ignition switch wire

Å Faulty or weak battery

Å Poor starter buttonconnectionÇ Faulty starter relayÉ Loose or disconnected

connector

Å Faulty starter motor

Å Faulty wire harness2. Starter motor turns slowly or idles

Å Weak or dead battery

Å Loose or disconnectedconnectorÇ Faulty starter relay

Å Seized cylinderÅ Broken or shorted

starter motor cableÇ Faulty starter pinion

3. Starter motor does not stop turning

Å Faulty starter pinion

Å Starter relay shorted orstuckclosed




Symptom

Symptom

Symptom





Stoplight does notcome on

Starter motorturns

Turns easily

Not stopped

Stoplight comeson

Starter does notturn

Hard to turn

Stopped

Relay operates properly

Starter motor turns slowly

Probable Cause

Probable Cause

Probable Cause

Relay does not operate

Starter motor turns normally

Check operation ofstop switch byapplying brake.

Check batterycircuit by operatingturn signals.

Check batterycircuit by operatingturn signals.

Turn ignition switchOFF.

Check operation ofstarter relay bydepressing starterbutton.

Connect startermotor directly tobattery.

Connect startermotor directly tobattery.

Rotate crankshaft.

GENERAL INFORMATION - Sell Files and Downloads ... INFORMATION 2-8 ZX / SCOUT 50 TORQUE VALUES...

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Transcript of GENERAL INFORMATION - Sell Files and Downloads ... INFORMATION 2-8 ZX / SCOUT 50 TORQUE VALUES...