Picked up a '02 ZX50

[buickid]

Hey all!  New owner of a used ZX50 here.  Picked it up for $300, knowing it had sat for a while.  Got about 149xx km on the clock, but was told it ran well before it sat.
Anyway, I was originally just going to pull the carb and clean it, but when I took it apart, I discovered it was a oily mess in there.  So sometime this week, I hope to take it outside, spray it with degreaser and clean it up so I can work on it a little easier.  I noticed the oil pump moves around, is that normal?  From reading the service manual, it would seem that its only held in with a rubber o-ring.  It would seem that its been dropped quite a few times in its life as well, the brake levers ends are bent, and many of the body plastic mounting tabs are broken.  I was going to try and epoxy them back on, unless anyone had a better idea for repairing them.  I took apart most of the switches, as they were very gritty and sticky feeling.  Any advice/comments are welcome!

A few pictures of the new scooot are in order!

[Hoolander2]

Hey, buickid, and Welcome to the forum!  You're no stranger to wrenching, I see.  Good that you're going through it so completely at the start.  A few of the regular ZX guys here have not been here much lately, due to either jobs, or connectivity issues I reckon.  I'm not a ZX owner but there are some here who will be able to answer your questions. 

I see that a fair amount of oil has covered the CVT on your scoot -- if it were me, I'd have a look inside there to see if oil got on the belt, variator, etc.  You prob already thought of that. 

[Shaka]

Looks like a fun project!    Yes, the oil pump does move around a little.  It is not really mounted besides the o-ring to seal it and then a bracket which has a tab over the top of the pump which keeps it from "popping" out.  The oil pump will wiggle a little in the hole though.  From the looks of all that oil on the engine, that may have been due to a leaky o-ring on the oil pump.  I had problems with that myself and just ended up removing the pump entirely and plugging the hole.  I have a thread on here somewhere about how I did it.  I would also highly recommend doing a leak-down test once you get it back together to be certain everything is sealed up properly!  This has saved my engine many times and I can't stress it's importance enough! There is definitely a leak somewhere which you need to remedy before you run the engine.  Good luck and keep everyone posted on your progress!

[buickid]

Hey thanks for the warm welcome guys!  I definately hear a leak when I turn the engine over slowly with the kick starter.  The oil pump gear goes directly into the crankcase I'm guessing, so if the o-ring is worn, the air would be leaking from there?  Does anyone know the size of the o-ring that fits on there? Also, what are other potential leak points beside the oil pump o-ring?  The only other place I can think of would be the intake manifold.  I'm sure once I get all the oil off this thing I'll be able to see what I'm dealing with a little better haha.  Any known weak points of the ZX, besides the CDI when unrestricted?
Oh and as far as performance parts go, does everything (motorwise) from the Dio fit?
Thanks again!

[Shaka]

I want to say the o-ring is 19mm x 2mm can't remember for certain though.  I was able to get one at my local Advance Auto.  Yes, the oil pump goes directly into the crankcase and engages a worm gear on the crankshaft.  The leak could also be coming from the intake manifold.  I'm sure you'll be able to get a better idea once you get all the oil cleaned off.  There are not really any other weak points I can think of.  Not all of the Dio parts are interchangeable either.  I know that final reduction gears are different and possibly some of the other cvt parts as well as the cdi.  I believe that motorwise the cylinders and what-not are interchangeable.

[buickid]

Okay great!  Can't wait till I have time.  I was working on an beater Aprilia that I also bought, and ended up tearing the stupid aircleaner box to carb rubber boot.  Since when are these things made of rubber    Theres no awesome site like Stadium Yamaha for Aprilia parts either

[buickid]

Alright, the Aprilia is done, and its ZX50 time!  Got most of the motor cleaned up, still working on it though.  Got the oil pump off, and the brass bushing and corresponding part of the oilpump are worn down so much, theres a groove in both!  Any idea how this happened?  I guess I'm going to have to buy a new oil pump and bushing...  In the mean time, I'm working on scraping the carbon off the cylinder head.

[thebatman]

I missed this but my oil pump has a bolt that holds it in place, not just the o-ring... If the bolt is in place, my pump cant move.........


@ hoo, HEy bro... hope all is well with you these days.....(there are a cpl ppl that keep a few of us away these days, not the jobs.)... I miss the old forum....

[buickid]

Yeah I think there are two bolts that hold it in place, but the hole that the bolt goes through is toast, apparently from the pump rocking back and forth too much or something...

[glopezz05]

Going off topic...

what mtb is that?  I love taking my gary fisher out to the trails.

[buickid]

That my baby! 2009 Specialized RockHopper Expert, changed the brakes from some Tektro hydraulics (leaked at -10F), to some Avid BB7s (203/185 F/R), some DMR V8 pedals, XTR front shifter, and other little assorted bits.  Great commuter, only hit the trails a few times (but tear up the streets for sure!)

[glopezz05]

nice!  got a GF 29er...  Full XT and juicy 3 brakes.  love it.

[buickid]

Nice, 29" must be pretty sweet 

[buickid]

Okay, this thing is slowly getting done, but I've run into a problem.  I was gonna change the gasket on the reedcage, so I took the reeds off, then tried to take the reedcage off.  Well its stuck to the manifold, and bits of it have chipped of in the process of trying to remove it.  So I need a new reedcage now.  Anyone know where I can pick one up cheap, or maybe find a used one?

[thebatman]

Pics??
 How much "chipped" off?  If minute, you may be able to just use a thick coat of gasket maker to get by.... Acually, from the dealer it'll be about $30-35 ...(from my local dealer) stadiumyamaha.com has some real good prices on oem parts.... You could also get a 4 patal reed design and install. v-force is the top dog.. ebay has intakes,reed cage for around $35. (just be sure to get the correct carb flange)