ZX trans how-to

steffen707 · Post by **steffen707** » Sat Dec 05, 2009 7:08 pm

Gotcha, any idea if a kymco cover works just as well as the sym?

I bet this is why my kick start binds on my elite, I don't think there is a gasket from the case to the cover. DOH!!!!

ldrancer · Post by **ldrancer** » Fri Dec 11, 2009 7:12 pm

me no no english

Wheelman-111 · Post by **Wheelman-111** » Tue Dec 15, 2009 11:15 pm

Greetings:

I thought I'd start small. So did my Financial Advisor, Ms. Wheelperson. EvilOne described some differences between the Honda and Kymco fixed pulleys. (The geared one opposite the variator...) For $20, I thought I'd find out for myself:

Surprisingly, the Kymco looks like a much more detailed bit of machining. If I could take a pic that's worth a darn, you could see machine hash-marks and neat radial grooves between the teeth on the kickstarter castle. The whole pulley looks like a better-finished, more engineered product.

Dimensions are the same in diameter and of course the 30-degree angle has to be the same to use the 30-degree belt. However the gear teeth that engage the starter Bendix look thicker, and again, machined with 2-angle cuts where the Honda's are straight.

The "Boss" on the belt side of the Kymco appears thinner, but measures within 0.2mm because the curve of the drive face doesn't have that "lip" that Evil mentions.

That's the Honda pulley on top.
Finally, this pic shows how much more the Honda kickstart castle sticks up:

I think this is the main reason why it's necessary to shim out the stock Honda cover to prevent the kickstarter mechanism from catching on the castle with the longer drive boss. Note how the Kymco pulley lies flat, while the Honda rests on the castle. The first pic suggests how much thicker this assembly is on the Honda. It measured out almost 2mm Thicker than the Kymco. The Kymco castle is actually a little recessed from the pulley dish, but not much.

Weights were within 7 grams, the Kymco slightly lighter. Both are steel.

Installed it tonight. Kickstarter and E-start work normally. Note that I have a pulley boss shimmed out 1.07 mm to accommodate my Polini 248-006 belt with the stock rear pulleys. (for now...

)

If you're thinking you need to mess with triple-gaskets, shim out the belt cover or pay $50 for a Kymco cover, there's a possibility that this $20 pulley will solve your problems with the ZX conversion. I'm still debating whether I want to do this or not. The longer belt and boss shim have my take-offs back to at least decent, but I sure wouldn' mind the wheelie capability promised by the bigger rear ZX pulleys. 50 cc wheelies impress the fair damsels. Well, the really nerdy ones, anyway.

steffen707 · Post by **steffen707** » Wed Dec 16, 2009 1:05 pm

That is very cool. Thank you for all the recon work!

sanjuro · Post by **sanjuro** » Wed Dec 16, 2009 3:55 pm

That's excellent recon work indeed. I've got a spare set of ZX drive face and rear pulley assembly for cheap if somebody is interested.[/threadjack]

Wheelman-111 · Post by **Wheelman-111** » Wed Dec 16, 2009 3:58 pm

Greetings:

PMed.

evilone · Post by **evilone** » Wed Dec 16, 2009 4:38 pm

Thanks for the post wheelman. So that drive pulley has a "boss" on it and the kick start gear is welded to pulley? Interesting since the drive pulley i have does not have a "boss" at all, it's completely smooth, and the starter gear is a seperate piece. (note 5th pic from top at start of topic). The "no boss issue" would explain why the belt rides lower than i think it should and why i planned on using my stock pulley since it spaced it out and let belt ride higher on rear pulleys. Thanks again, looks like my pulley is not off a ZX. I'll have to make a note at start of thread.

Wheelman-111 · Post by **Wheelman-111** » Wed Dec 16, 2009 4:46 pm

Greetings:

The kickstart castle looks like it's integral to the pulley dish. If it's "welded" on, it is a darned good, seamless weld that I suspect only a robotic welder could perform.

"Boss" may not be the right term for the shape of the other side, but one of my "pics" shows how the Honda pulley has a cylindrical protrusion that is a bit more proud of the belt surface than the Kymco's.

evilone · Post by **evilone** » Wed Dec 16, 2009 4:51 pm

I looked at Kymco website and saw the ZX is the only model with GAH in part#. All the others had KEB7 (which is what mine has stamped into it). Also shows the ZX pulley is 1 piece while the others are not.

evilone · Post by **evilone** » Wed Dec 16, 2009 4:53 pm

Whoops, writing at the same time

. The drive face i have has no "cylindrical protrusion". Thanks again. I edited post with a note to see page 5 for drive pulley update.

evilone · Post by **evilone** » Wed Dec 16, 2009 5:23 pm

mookie wrote:
i dont see a part number for the belts....

23100-KCX-9000 is the Kymco ZX belt part number. $36.67
I'm not positive the Kymco belt is the same size as Dio ZX?

mookie · Post by **mookie** » Sun Dec 20, 2009 9:47 am

i bought NEW the ZX clutch assembly and a new 18 669 32 belt.
for sale never used mounted nothing

90 shipped.no i won't take or consider lowball offers, but hey-Thanks

Mookie

mookie · Post by **mookie** » Fri Dec 25, 2009 11:27 am

new and never mounted. anyone?

evilone · Post by **evilone** » Fri Dec 25, 2009 12:40 pm

Honda, Kymco, or Sym? I still want a pic of the weld on stationary pulley

mookie · Post by **mookie** » Fri Dec 25, 2009 6:18 pm

KYMCO ZX 50
what is a weld on stationary pulley???
this whole thread was started i believe using this exact clutch assembly.

it is a direct bolt on with case trimming.
not sure what it is your after.

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