You've got a Ignition System Issue which narrows things down quite a bit. It's either the ignition switch that your key goes into, or an on/off(run/stop) switch, or it's a relay for the ignition systems(or starter relay), if it's none of those then it's the starter solenoid that you've been jumping with the screwdriver, it sounds like the starter is working as it should since it turns over- the reason it turns over but won't actually run is because the ignition system won't work unless the key is inserted and in the run position, or if there's any other on/off switch that controls your engine it could be there. I'm not familiar with this exact bike but this is a common issue with all motorized machines! You can bypass all of this but that requires running some wires and a couple of switches plus a relay or two- that's an option but don't do that as your issue is nothing major and would be easier to fix than to go through the trouble of re-wiring it all. Just start troubleshooting and eliminate one part at a time, check relays, fuses, and electrical connections first, then the individual components I listed above and check to make sure they have power coming in and out when/where they're supposed to. If your bike turns over but won't run and the key is on, and you have a functional Ignition system then you need to verify you have ignition by checking your coil's output. EASIEST way to do so is pull a spark plug and connect it to the spark plug wire as you normally would, then hold the spark plug against the engine to ground it and turn it over- you'll see if you have any spark jumping aroundbetween the spark plug's electrode and the base of the plug itself. Either way, you'll get this figured out now that you know where to start and what to check!
Check all wiring connections and especially those on the battery, starter, and starter solenoid(if seperare from battery). It sounds like something is just making a bad connection since it won't even turn over- I bet your problem is in this area, good Luck and if I've been helpful please click the green button to let me know, Habe A Great Day!
Can be a loose / bad connection somewhere in the high current starter circuit, or a flat battery.
Did it start ok a few times when you put in the new battery?
Yes >> not charging the battery (or not charged when fitted).
No >> Bad connection between battery and frame or between battery and main ignition key power connection point (usually to a fuse).
The cause of solenoid clicking is the voltage dropping dramatically when the starter current begins to flow, usually a flat battery or a loose or dirty connection in the starter current circuit (will generate heat when clicking which can help you find it).
Your first option is to check the basics.
Is there fuel in the tank? Yes, I know that sounds silly but I have done it!
Check that the fuel lines all the way from the tank aren't blocked.
Is there a fuel tap, (petcock), fitted? They usually have a gauze filter built into them that might need cleaning.
Is the fuel filter a new one?
When was the last time the carb was overhauled?
Hi, Pete you may have squeaked your top end this is commonly known as "HEAT SEIZE" the piston heats up expands and becomes extremely tight in the cylinder bore and usually occurs mainly on 2 cycle engines right after a fresh top end rebuild, but it can also happen to brand new motorcycles, these are rare instances due to better quality control and education. Overheating failures that cause pistons to seize are many and each one should be carefully diagnosed to prevent future repeat offenders and the usual suspects are:
1. Lack of lubrication due to low or no oil.
2. Among the causes of lack of cylinder, lubrication is clogging of lubricator by dirt or waste, obstruction in oil pipes/lines, leaky check valves, leaky pump packing, broken oil pipe/line, oil too cold to feed.
3. Wrong type of oil used in premix or oil tank.
4. Improper premix ratio you should start with 32:1 as a baseline.
5. New rebuild piston to cylinder tolerances set up too tight.
6. Failure to follow proper break-in procedures with a 16:1 premix ratio.
7. Loose fasteners causing intake, base, or head gaskets to leak or blown crankshaft seal, failure caused by age, overheating or walking.
8. Holes in the intake manifold bent or warped intake flange or reed cage any stray air coming into a cylinder will cause a super lean condition.
9. Improper assembly of reed valve gaskets.
10. Insufficient warm-up time for temperature conditions before WOT.
11. Broken, pinched or cracked fuel line.
12. Carburetor fuel passages clogged or restricted from stale fuel varnish, ethanol sludge, dirt, rust, or fuel level in float bowl too low.
13. Main jet size too small or partially clogged
14. Air filter improperly installed, missing or not sealing.
15. Faulty or improperly adjusted oil pump and or cable.
16. Failure to bleed oil pump after a rebuild/replacement or running oil tank dry.
17. Engine coolant level too low, too old, or improper mixture ratio.
18. Radiator clogged, fins damaged, or faulty cap.
19. No liquid circulation due to failed oil or water pump.
20. Cavitation due to air in oil or coolant system.
21. Water and oil mix due to a blown head gasket.
22. Timing retarded due to faulty CKP sensor or CDI.
23. Improper spark plug heat range (too hot) and or gap.
24. Excessive engine load, brakes dragging, clutch slipping, transmission lubricant level too low or viscosity to high.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day. Kymco ZX50 SC10 motor build AF16 clone 49ccScoot com Scooter Forums 50cc KICKSTARTER PROBLEMS AND SOLUTIONS KYMCO ZX Service Manual Fever 1 50 ZX50 KCA SA10AL Kymco Scooter Parts Racing Planet USA KYMCO ZX 50 User Manual
Hi, Graeme the vast majority of service, parts fiche, and owners manuals on the internet are "FREE" to download and all service manuals contain wiring diagrams in the back pages. The rest usually charge a modest fee of $15 and there is a handful of obscure, rare, obsolete, and very old models that are no longer or never were available and some were never printed in English. The Indian and Philippine markets are usually in E-book format only, for these rare occasions I shall look on eBay and find the cheapest one available. Most of the manuals will cover your exact make, model, and year otherwise one will be provided that comes as close as possible to your bike and will have most of the same info that an exact manual would have. If there is no $ sign after the manual link it is free to download.
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