KYMCO ZX 50 User manual

Dear KYMCO Motorcycle Users:
Before the delivery of each new motorcycle, the fuel in carburetor is
drained off to ensure the excellent performance and safety of the
motorcycle. Therefore, when first starting a new motorcycle, it is
normal to take 20～30 seconds. The quality of each KYMCO
motorcycle is guaranteed.

Dear Users:
We greatly appreciate your patronage of KYMCO ZX 50
This User‘s Manual describes the correct operating methods, inspection and
maintenance procedures for the KYMCO ZX 50 in details in order to prolong
the service life of motorcycle and provide you with a comfortable riding.
Please note that the information and illustrations included in this manual may be
different from the motorcycle in case specifications are changed.
To enable you to have a safe and comfortable riding, we recommend you to read
this manual carefully and wish you a happy riding.
Note: 1. The information and specifications stated in this manual are for reference only
and subject to change without notice.
2. When starting the engine, the battery must be installed to facilitate starting
and increase the engine performance.

TABLE OF CONTENTS
1. PRECAUTIONS FORA SAFE RIDING................................................................. 1
2. ASSEMBLY PARTS................................................................................................... 3
3. OPERATION INSTRUCTIONS............................................................................... 5
4. PRE-RIDE INSPECTION....................................................................................... 10
5. ENGINE STARTING METHODS ......................................................................... 18
6. NORMAL RIDING METHOD............................................................................... 21
7. PRECAUTIONS FOR RIDING............................................................................. 23
8. HOW TO STOP RIDING........................................................................................ 26
9. EASY MAINTENANCE.......................................................................................... 28
10. IMPORTANT NOTICES ........................................................................................ 35

-1-
1. PRECAUTIONS FOR A SAFE RIDING
(1) CLOTHES
yTo relax and wear comfortable clothes are the
main points for a safe riding.
yTo observe traffic laws, keep a cool mind, relax
and be careful will provide you a safe riding.
cWear helmet and fasten it tightly.
dHave the clothes well-arranged. Fasten shirt
cuffs and keep them from hooking the brake
lever.
eWear low-heeled shoes for a safe riding.
fWhen riding, use both hands to grasp the
handlebar. It is very dangerous to hold the
handlebar with one hand.
nCAUTION:
yA motorcycle rider should not wear loose or too
long clothes to avoid danger.
yDuring riding or 10 minutes after the motorcycle
is stopped, do not touch the exhaust muffler to
avoid scalding.
yWhen parking the motorcycle, keep it away from
dry lawn or inflammables to avoid danger.
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-2-
(2) RIDING METHOD
yThe safety of two-wheel vehicles is influenced by
sitting position. The rider should sit on the central
part of the seat cushion. If the rider sits on the
rear part of the seat, the load of front wheel will
decrease. As a result, the handlebar will swing
and cause danger to the rider.
yWhen making a turn, it will be easier for the rider
to steer the motorcycle by leaning the body inward
slightly. The motorcycle will lose its balance if the
rider fails to keep his body leaning inward.
yWhen riding on a damaged or macadam road.
Slow down the speed and hold the handlebar
tightly.
(3) CARRYING GOODS
yKeep a good sitting posture to operate the
motorcycle properly.
yThe feel of the handlebar will be different when
carrying goods on the motorcycle. Overloading
may cause the handlebar to swing. Avoid riding
with overload.
cMax. loading capacity of the met-in box is 10kg.
dMax. loading capacity of the front tool box is
1.5kg.
eMax. loading capacity of the rear carrier is 5kg.
cd
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-3-
2. ASSEMBLY PARTS
Engine
Serial No.
Helmet Buckle
Seat Lock
Taillight
/
Stoplight
Air Cleane
r
Kick Leve
r
Battery
L. Front Turn
Signal Light
Rear Brake Leve
r
Passing Signal
Switch
Turn Signal Switch
Headlight Dimmer
Switch
Frame Serial No.
VIN (Vehicle
Identification No.)

-4-
Starter Button
Met-in Box
Fuel Fille
r
Exhaus
t
Muffler
Main Stand
Front Tool Box
Taillight
/
Stoplight
Headligh
t
Front Brake Leve
r
Headlight Switch
R. Front Turn
Signal Light
R. Rear Turn
Signal Light

-5-
3. OPERATION INSTRUCTIONS
(1) IGNITION SWITCH/STEERING
HANDLEBAR LOCK
cOFF :At this position, power is cut off and the
engine stops. The key can be taken out.
dON :At this position, power is connected to
start the engine. The key cannot be
taken out.
eLOCK :At this position, the steering handlebar
is locked. The key can be taken out
《Locking Method》
Turn the steering handlebar left to the full and then
press to turn the ignition switch key to “LOCK”
position and the handlebar is locked.
《Unlocking Method》
Turn the key to “OFF” and the lock is released
automatically.
nCAUTION:
yAfter locking, turn the handlebar gently to make
sure that it is locked.
yDo not turn the ignition switch to “LOCK”
during riding, or the handlebar will be out of
control and cause accidents.
yDon‘t park your motorcycle at a place to hinder
the traffic.
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-6-
(2) STARTER BUTTON
yTo start the engine, first turn on the ignition
switch and then press the starter button. At this
time, be sure to fully apply the front or rear brake
lever (pedal) in order to connect the power.
nCAUTION:
yDuring engine running, do not push the starter
button to avoid engine damage.
yTurn the headlight switch and turn signal switch
“OFF” before using the starter button.
yRelease the starter button immediately after the
engine is started.
(3) HEADLIGHT SWITCH/ HAZARD SWITCH
zAt this position, the position light,
headlight, instrument lights and taillight go
out together.
At this position, the position light, instrument
lights and taillight light together.
At this position, the position light, headlight,
instrument lights and taillight light together.
At this position, the front and rear right and
left turn signal lights wink together.
At this position, the front and rear right and
left turn signal lights go out together.
▲
●

-7-
(4) HEADLIGHT DIMMER SWITCH/
PASSING SIGNAL SWITCH
cSwitch to this position for using high
beam.
dWhen riding in downtown area or there is
a car coming from the opposite direction,
use low beam to avoid affecting the
visibility of coming cars.
ePASSING When passing, continuously press and
release the dimmer switch at the
PASSING position and the headlight
will wink to warn the coming cars.
(5) HORN BUTTON/TURN SIGNALSWITCH
yWhen the ignition switch is turned “ON”, press
the horn button and the horn will sound. cÖFor
turning to the right dÕFor turning to the left
ePush the turn signal switch button to release it.
fHorn Button
yThe horn and turn signal switch do not work
when the ignition switch is “OFF”.
nCAUTION:
yThe turn signal light will not release
automatically. Be sure to reset it after use;
otherwise it may affect the traffic safety.
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-8-
(6) SEAT LOCK/MET-IN BOX
yTo open the seat, insert the ignition switch key
into the seat lock and turn it right. Lift up the
seat.
yMax. loading capacity of the met-in box is 10kg.
yTo close the seat, put down the seat and press it
down to make it lock automatically. Then slightly
pull up the seat cushion to make sure that it is
locked.
nCAUTION:
yNever put the key under the seat cushion and lock
the seat.
(7)
HELMET BUCKLE
1.Open the seat lock and lift up the seat.
2.Put the helmet retaining ring into the helmet
buckle.
3.Put down the seat and it will lock automatically.
yTake out the helmet in the reserve order of the
above steps.
nCAUTION:
yWhen riding, wear the helmet and do not retain it
on the motorcycle to avoid damage of coated
parts.

-9-
(8) INSTRUMENTS
cMILEAGE COUNTER: The total riding mileage
is indicated by kilometer. The figure in black
and white is an unit of 100m.
dMOTOR OIL INDICATOR LIGHT: When the
ignition switch is “ON”, it is normal if the motor
oil indicator light comes on for several seconds
and then goes out. If the light does not go out, it
means that the motor oil is insufficient. Please
refill with the specified motor oil.
eSPEEDOMETER: The riding speed is indicated
by km/hour.
fTURN SIGNAL INDICATOR LIGHT: When
the turn signal switch is operated, this indicator
light will wink.
gFUEL GAUGE: The fuel gauge is to show the
volume of gasoline in the fuel tank. If the fuel
gauge pointer is at the red area, the fuel is
insufficient. Refill with 92# or 95# nonleaded
gasoline as early as possible.
nCAUTION:
yDo not add any additives when refilling fuel or
motor oil.
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-10-
4. PRE-RIDE INSPECTION
(1) ADVANCE INSPECTION
yGet into a good habit of inspection before riding.
For the sake of safety and to prevent vehicle
damage and traffic accidents, the pre-ride
inspection is absolutely required.
nCAUTION:
yBe sure to perform inspection and maintenance
for your new motorcycle after it is purchased for
one month or ridden for 300km.
(2) MOTOR OIL LEVEL INSPECTION/
REFILLING
yPlace the motorcycle on its main stand.
yOpen the seat and turn the motor oil tank cap
counterclockwise to open it.
yFill the oil tank with the recommended 2-stroke
motor oil and close the motor oil tank cap.
nCAUTION:
yWhen adding the motor oil, the oil level shall not
exceed the upper limit. Be careful not to allow
foreign matters or dust to enter the oil tank.
yUse of unspecified motor oil may cause poor
performance or engine damage.

-11-
(3) BRAKE INSPECTION．Ride the motorcycle
at low speed on a dry road and respectively apply
the front and rear brakes to check the brake
performance.
The brake lever should have proper free play.
”Free play” means the distance from the position of
loose brake to the position of fully applied brake.
Measure the free play at the brake lever end
and check if it is within the specified value of
1~2cm.
(4) TIRE INSPECTION
1. Tire Pressure Check
Check if the tire pressure is normal when the
tire is in contact with level ground.
If there is any abnormal condition, check the
tire pressure with a tire pressure gauge.
Measure the tire pressure under room temperature.
Rear Brake

-12-
2. CRACKS & DAMAGE
Check the tire-contact area for crack or
damage.
3. Abnormal Wear
Check the tire-contact area for abnormal wear.
4. FOREIGN OBJECTS OF METAL PIECE &
GRAVEL
Check the tires and tire-contact area for imbedded
objects of metal piece and gravel.
5. DEPTH OF TIRE GROOVE
If the tire is worn to the wear limit indication mark,
replace it with a new one.
NORMAL PRESSURE(1 Rider / 2 Riders )
Front Wheel 1.5/1.75 kg/cm²
Rear Wheel 2.0/2.25 kg/cm²
nCAUTION:
yAbnormal tire pressure, crack, damage and
abnormal wear will cause unsteady handlebar and
result in tire break.
yIf the tire has cracks or is worn to the wear
limit indication mark, replace it with a new
one.

-13-
(5) FUEL LEVEL INSPECTION/REFILLING
yCheck if the fuel is sufficient.
yIf the fuel gauge pointer is at “E” (red line), refill
with #92 or #95 nonleaded gasoline as soon as
possible.
《Refilling Method》
1.Open the seat with the ignition switch key. (Refer
to P8.).
2.Turn the tank cap counterclockwise with hand to
open the cap.
3.Use only #92 or #95 nonleaded gasoline.
4. Turn the fuel tank cap clockwise to tighten it.
The “△” mark on the fuel tank cap shall be
aligned with the “△” mark on the fuel tank.
5.Close the fuel tank cap in the reverse order of
opening.
cFuel tank cap dUnlock eLock
fReference plate
nCAUTION:
yBe sure to stop the engine before refilling.
yThe gasoline level shall not exceed the reference
plate; otherwise the fuel will penetrate out.
yWhen refilling, do not add other additives to
avoid engine breakdown.
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-14-
(6) STEERING HANDLEBAR
yVisually inspect the steering handlebar for
damage.
yApply the front brake and move the handlebar
upward and downward to check for abnormal
noise.
yMove the steering handlebar upward, downward,
rightward and leftward to check for any loose
parts.
yCheck if the handlebar rotates freely.
yIf any abnormal condition is found, go to your
motorcycle dealer for inspection.
(7) INSTRUMENT LIGHTS INSPECTION
yCheck the speedometer pointer for proper
operation.
yCheck the fuel gauge pointer for proper
operation.
yCheck the turn signal indicator lights for proper
operation.

-15-
(8) BRAKE LEVER FREE PLAY INSPECTION
& ADJUSTMENT
yAdjust the brake lever free play with the brake
adjusting nuts.
yAfter adjustment, fully apply the brake levers and
check if the free play is within the specified value
(1～2cm).
cIncrease play dDecrease play
nCAUTION:
yAfter the brake is adjusted, align the groove of
adjusting nut with the pin in order to avoid
accident and danger during riding.
(9) BRAKE SHOE INSPECTION
yWhen the brake lever is fully applied, if the mark
“△” on the brake indicator aligns with the
reference mark “△” on the brake panel, it means
the brake shoe is worn out. Go to our designated
distributors or service stations for brake shoe
replacing.
yBrake shoe service limit: cFront dRear
nCAUTION:
yBrake shoe will be worn more quickly if the
brake lever is always applied lightly during
riding.
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-16-
(10) HORN/LIGHTS INSPECTION
yTurn the ignition switch “ON” and press the horn
button to check if it sounds.
yHeadlight/Taillight Inspection:
Start the engine and turn on the headlight switch
to check if the headlight and taillight are good
and check the light shells for dirt and damage.
yStoplight Inspection:
Apply the front and rear brake levers respectively
to check if the stoplight is good. And also check
the stoplight shell for dirt and damage.
yTurn Signal Light Inspection:
Operate the turn signal switch to make sure
whether the right/left front and rear turn signal
lights can wink and buzz. Also check the light
shells for dirt and damage.
cHeadlight dTurn signal light eTaillight/
Stoplight fHorn button
nCAUTION:
yReplace any dirty or damaged lights with new
ones to avoid danger during riding.
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-17-
(11)FRONT/REAR SHOCK ABSORBER
INSPECTION
yCheck the condition of the front/rear shock
absorbers by pressing down the handlebar and
seat several times.
(12) BRAKE PERFORMANCE INSPECTION
yFully apply the front and rear brake levers and
move the motorcycle forward to see if the
braking effect is good.
(13) REARVIEW MIRRORANGLE CHECK
ySit on the motorcycle uprightly and make a
viewing test of the rearview mirror angle.
(14) LICENSE PLATE CHECK
yCheck the license plate for dirt and damage, then
tighten it.
(15) REFLECTOR CHECK
yCheck the reflector for dirt and damage.
(16) PREVIOUS ABNORMAL PARTS
INSPECTION
yMake sure that the previous abnormal parts are
repaired.
(17) LUBRICATION POINT CHECK
yVisually check if all motorcycle lubrication
points are lubricated properly.