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Messages - Calvert50

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zx50 / Re: ZX-50 Kick Starter
« on: August 19, 2009, 04:42:13 PM »
Zombie...

Thanks for the hint.  That was one of my theories, that the darn spring had to be wound one turn to be effective.  That makes sense.  I tried that with the old spring, and couldn't get it. It kept exploding out of the brackets.   I bet at the factory when they do the one wind, they have some kind of tool to make it easy.

So just to reiterate.  The spring has to be tensioned one turn up from neutral.  Ouch...that ain't gonna be easy. 

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zx50 / Re: Kymco Cobra Cross 50cc- bogs down and dies when it gets hot
« on: August 17, 2009, 06:23:54 PM »
I had some similar symptoms with my ZX-50.  It acted like gas starvation or an intermittment spark plug.  I checked the fuel filter and replaced the spark plug. It still acted up.

As others have said, the CDI unit turned out to be the problem.   They don't just up and die completely.  They'll work sometimes and not other times.  Sometimes they'll cut out at higher rpms, thus mimicking a gas problem or a spark plug issue.   

However if you have the service manual and a voltmeter and you're handy with this stuff, you can measure all the CDI voltage parameters.  This was the dead giveaway with my problem.   I replaced it, and it started and ran perfectly.

I vote for a CDI problem.

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zx50 / ZX-50 Kick Starter
« on: August 17, 2009, 05:58:56 PM »
I'm having an issue with the ZX-50 kick starter.  This is a 2003 model.  The machine fell over and jammed the mechanism.  I took it apart and nothing is broken.  The circlip got pushed out of place and the kick starter return spring mechanism went "sprong".   I have the service manual, and put everything back together per the diagrams.  However the kick lever return seemed weak, and the gravity seems to pull the lever enough so that the kick starter "driven gear" engages the engine and makes metallic scrapping sounds when you hit bumps.   The manual does say "check for a weak spring", and since it says very little else, I figured that was worth replacing.  Five bucks later I have a new spring, but it has all the same angles as the old spring, and it just doesn't seem to have enough umph to hold up the rather light weight of the kick start lever, and once again, while it works and starts the engine, when you drive down the road, bumps and gravity pull the lever down, thus slightly engaging the kick starter "driven gear". 

What I'm wondering is whether the kick starter return spring should be spun up one turn to add tension.  The shop manual says nothing about this.   I've lubbed up the "driven gear" shaft to make sure it's not sticking in the "engage" position.   It appears that the spring is made to just be installed without adding one revolution of tension, which I tried to do, and it's virtually impossible to do that, and just didn't seem to make sense.   Though the additional tension would solve the problem I think if I could wind it up that tight.   

Anbody run into this problem?

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