Kymco MO ZX50 Service Manual - chap 13 (manubrio ruota freno sospens ant)

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

13-0

ZX / SC OUT 50

13

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STEERING HANDLEBAR/FRONT WHEEL/FRONT

BRAKE/FRONT SHOCK ABSORBER/FRONT FORK

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SERVICE INFORMATION........................................................ 13- 2

TROUBLESHOOTING.............................................................. 13- 2

STEERING HANDLEBAR ........................................................ 13- 3

FRONT WHEEL....................................................................... 13- 5

FRONT BRAKE (DISK BRAKE) ............................................... 13- 9

FRONT SHOCK ABSORBER..................................................... 13-17

FRONT FORK .......................................................................... 13-20

13

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

13-1

ZX / SC OUT 50

4.5kg-m

2.7kg-m

6.0kg-m

3.3kg-m

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

13-2

ZX / SC OUT 50

SERVICE INFORMATION

SPECIFICATIONS

Item

Standard (mm)

Service Limit (mm)

Axle shaft runout

æ

0.2

Radialæ2.0

Front wheel rim runout

Axialæ2.0

Front brake drum I.D.

110

111

Front brake lining thickness

4.0

2.0

Front shock absorber spring free length

200

182.8

Brake disk thickness

35_ 3.8

3.0

Brake disk runout

æ

0.30

Brake master cylinder I.D.

12.700_ 12.743

12.75

Brake master cylinder piston O.D.

12.657_ 12.684

12.64

Brake caliper piston O.D.

25.400_ 25.405

25.45

Brake caliper piston I.D.

25.318_ 25.368

25.30

TORQUE VALUES

Handlebar lock nut 4.0_ 5.0kg-m Front damper nut 1.5_ 3.0kg-m
Steering stem lock nut 8.0_ 12.0kg-m Front axle nut 5.0_ 7.0kg-m
Steering top cone race 0.5_ 1.3kg-m Brake arm bolt 0.4_ 0.7kg-m

SPECIAL TOOLS

Lock nut wrench Driver handle A
Lock nut socket wrench Outer driver, 37x40mm
Outer driver, 28x30mm Pilot, 10mm
Rear shock absorber remover Bearing puller
Rear shock absorber compressor Snap ring pliers (close)
Ball race remover Damper compressor

TROUBLESHOOTING

Hard steering (heavy) • Contaminated brake disk or disk pad

• Excessively tightened steering stem top • Worn brake bushing
cone race • Worn brake master cylinder piston oil seal

• Broken steering balls • Clogged brake fluid line

• Insufficient tire pressure • Deformed brake disk

Steers to one side or does not track straight • Unevenly worn brake caliper

• Broken clutch weight spring Front wheel wobbling

• Bent front fork • Bent rim

• Bent front axle or uneven tire • Loose front axle

Poor brake performance • Bent spoke plate

• Incorrectly adjusted brake • Faulty tire

• Worn brake linings • Improperly tightened axle nut

• Contaminated brake lining surface Soft front shock absorber

• Worn brake cam • Weak shock springs

• Worn brake drum • Insufficient damper oil

• Poorly connected brake arm Front shock absorber noise

Poor brake performance (disk brake) • Slider bending

• Air in brake system • Loose fork fasteners

• Deteriorated brake fluid • Lack of lubrication

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

13-3

ZX / SC OUT 50

STEERING HANDLEBAR

REMOVAL

Remove the handlebar front and rear covers.
(!12-3)
Remove two bolts attaching the left brake
lever holder.
Remove two bolts attaching the brake
master cylinder (disk brake) to the right
brake lever.

Remove the two right handlebar switch
housing bolts and separate the housing.
Disconnect the throttle cable and then
remove the throttle pipe from the
handlebar.

Remove the handlebar lock nut to remove
the handlebar.

Brake Master Cylinder

Bolts

Bolts

Throttle Pipe

Throttle Cable

Bolts

Handlebar

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

13-4

ZX / SC OUT 50

INSTALLATION

Install the handlebar, aligning the tabs of the
handlebar with the grooves in the steering
stem.
Install and tighten the handlebar lock nut.

Torque: 4.5_ 5.0kg-m

Lubricate the throttle pipe front end with
grease.
Install the throttle grip and connect the
throttle cable.

The installation sequence is the reverse of
removal.
Install the rear brake lever holder.
Install the front brake master cylinder (disk
brake).

Brake Master Cylinder

Tab/Groove

Holders
Throttle Cable

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

13-5

ZX / SC OUT 50

FRONT WHEEL

REMOVAL

Jack the motorcycle front wheel off the
ground.

Remove the speedometer cable set screw
and disconnect the speedometer cable.
Remove the front axle nut and pull out the
axle.
Remove the front wheel.
Remove the brake panel side collar.

INSPECTION

Set the axle in V blocks and measure the
runout.
The actual runout is _ of the total indicator
reading.

Service Limit: 0.2mm replace if over

Axle Nut

Speedometer Cable

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

13-6

ZX / SC OUT 50

Check the wheel rim runout.
Service Limits:
Radial: 2.0mm replace if over
Axial: 2.0mm replace if over

Turn the wheel bearings and replace them if
they have excessive play or noise.

DISASSEMBLY

Remove the dust seal.

Dust Seal

Play

Radial

Axial

Play