KYMCO Super 8 50 User manual

Super 8 50
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO
SUPER 8 50
Section 1 contains the precautions for all
operations stated in this manual. Read
them carefully before starting any
operation.
Section 2 is the removal/installation
procedures for the frame covers which
are subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part, starting
from periodic maintenance.
Sections 6 through 17 give instructions
for disassembly, assembly and inspection
of engine, chassis frame and electrical
equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION
1
FRAME COVERS/EXHAUST MUFFLER
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
ENGINE
FUEL SYSTEM
5
ENGINE REMOVAL/INSTALLATION
6
CYLINDER HEAD/VALVES
7
CYLINDER/PISTON
8
DRIVE AND DRIVEN PULLEYS
9
FINAL REDUCTION
10
CRANKCASE/CRANKSHAFT
11
CHASSIS
FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12
REAR WHEEL /REAR BRAKE /REAR
SUSPENSION
13
ELECTRICAL EQUIPMENT
BATTERY/CHARGING SYSTEM/A.C.
GENERATOR
14
IGNITION SYSTEM
15
STARTING SYSTEM
16
LIGHTS/INSTRUMENTS/SWITCHES
17
EXHAUST EMISSION CONTROL
SYSTEM
Our company reserves the right to make
any alteration in the design.The
information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.
18

1. GENERAL INFORMATION
1-1
SUPER 8 50
Location of Engine Serial Number
Frame Serial Number
1
ENGINE SERIAL NUMBER
1
ENGINE SERIAL NUMBER ...................1- 1 LUBRICATION POINTS........................1-13
SPECIFICATIONS....................................1- 2 CABLE & HARNESS ROUTING.............1-15
SERVICE PRECAUTIONS......................1- 3 WIRING DIAGRAM................................1-20
TORQUE VALUES ..................................1-11 TROUBLESHOOTUNG...........................1-21
SPECIAL TOOLS .....................................1-12

1. GENERAL INFORMATION
1-2
SUPER 8 50
SPECIFICATIONS
Motorcycle Name & Type
SUPER 8 50
Name & Model No.
KP10BA(AAB6)
Overall length (mm)
2040
Overall width (mm)
740
Overall height (mm)
1140
Wheel base (mm)
1365
Engine type
Air cooled 4-stroke
Displacement
50cc
Fuel Used
92# nonleaded gasoline
Front wheel
45
Net weight (kg)
Rear wheel
67
Total
112
Front wheel
861
Max weight(kg)
Rear wheel
176
Total
262
Tires
Front wheel
120/70 -14
Rear wheel
120/80 -14
Ground clearance (mm)
130
Perform-
Brakingdistance (m)
2.0 (Initial speed
30km/h)
ance
Min. turning radius
(mm)
L:2060/R:2050
Starting system
Starting motor
Type
Gasoline, 4-stroke
Cylinder arrangement
Single cylinder
Combustionchamber type
Semi-sphere
Valve arrangement
O.H.C.
Bore x stroke (mm)
∮39*41.4
Compression ratio
10.5
Compression pressure
(kg/cm²-rpm)
16±2
Max. output
2.4kw/7500rpm
Engine
Max. torque
3.2NM/6000rpm
Intake
Open
-4
Port
Close
12
timing
Exhaust
Open
20
Close
-8
Valve clearance
Intake
0.04
0.04
(cold) (mm)
Exhaust
0.04
0.04
Idle speed (rpm)
2000rpm
2000rpm
2000rpm
Lubricatio n System
Lubrication type
OIL PUMP
Oil pump type
Cycloid type
Oil filter type
Full-flow filtration
Oil capacity
0.7 liter
Cooling Type
Forced air cooling
Forced air cooling
Air cleaner type & No
Paper element
Fuel capacity
6.0 liter
Carburetor
Type
-----
Piston dia. (mm)
------
Venturi dia.(mm)
--
Throttle type
Type
ECU
Ignition timing
BTDC 13°~ 28°
Contact breaker
Non-contact point type
Spark plug
NGK CR7HSA
Spark plug gap
0.6～0.7mm
Battery
Capacity
12V8AH
Clutch
Type
Dry centrifugal type
Type
CVT
Operation
Stepless automatic
transmission
Type
Two-stage reduction
Reduction
1st
0.8-3.1
ratio
2nd
11.05
Front
Caster angle
27
Axle
Trail length

Tire pressure
Front
1.75
(kg/cm²)
Rear
2.25
Turning
Left
45
angle
Right
45
Brake system
type
Front
DISK
Rear
Drum
Suspension type
Front
FR:TELESCOPE
Rear
RR:UNIT SWING
Shock absorber
distance
Front
80
Rear
82
Frame type
Pipe Under Bone
Fuel System
Electrical Equipment
Ignition System
Power Drive System
Transmis- sion Gear
Reduction Gear
Moving Device
Damping Device

1. GENERAL INFORMATION
1-3
SUPER 8 50
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
Use genuine parts and lubricants
.
When servicing the motorcycle, be sure to
use special tools for removal and
installation.
After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.

1. GENERAL INFORMATION
1-4
SUPER 8 50
Apply or add designated greases and
lubricants to the specified lubrication
points.
After reassembly, check all parts for proper
tightening and operation.
When two persons work together, pay
attention to the mutual working safety.
Disconnect the battery negative (-) terminal
before operation.
When using a spanner or other tools, make
sure not to damage the motorcycle surface.
After operation, check all connecting points,
fasteners, and lines for proper connection
and installation.
When connecting the battery, the positive
(+) terminal must be connected first.
After connection, apply grease to the
battery terminals.
Terminal caps shall be installed securely.

1. GENERAL INFORMATION
1-5
SUPER 8 50
If the fuse is burned out, find the cause and
repair it. Replace it with a new one
according to the specified capacity.
After operation, terminal caps shall be
installed securely.
When taking out the connector, the lock on
the connector shall be released before
operation.
Hold the connector body when connecting
or disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is bending,
protruding or loose.
Confirm
Capacity

1. GENERAL INFORMATION
1-6
SUPER 8 50
The connector shall be inserted
completely.
If the double connector has a lock, lock
it at the correct position.
Check if there is any loose wire.
Before connecting a terminal, check for
damaged terminal cover or loose
negative terminal.
Check the double connector cover for
proper coverage and installation.
Insert the terminal completely.
Check the terminal cover for proper
coverage.
Do not make the terminal cover opening
face up.
Secure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the insulated
surfaces contact the wire harnesses.
Snapping!

1. GENERAL INFORMATION
1-7
SUPER 8 50
After clamping, check each wire to make
sure it is secure.
.
Do not squeeze wires against the weld or
its clamp
After clamping, check each harness to
make sure that it is not interfering with any
moving or sliding parts.
When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
Route wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
No Contact !

1. GENERAL INFORMATION
1-8
SUPER 8 50
Route harnesses so they are neither
pulled tight nor have excessive slack.
.
Protect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner
When rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
Do not break the sheath of wire.
If a wire or harness is with a broken sheath,
repair by wrapping it with protective tape
or replace it.
When installing other parts, do not press or
squeeze the wires.
Do not pull
too tight!
Do not press or
squeeze the wire.

1. GENERAL INFORMATION
1-9
SUPER 8 50
After routing, check that the wire harnesses
are not twisted or kinked.
Wire harnesses routed along with handlebar
should not be pulled tight, have excessive
slack or interfere with adjacent or
surrounding parts in all steering positions.
When a testing device is used, make sure to
understand the operating methods
thoroughly and operate according to the
operating instructions.
Be careful not to drop any parts.
When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Do not bend or twist control cables.
Damaged control cables will not operate
smoothly and may stick or bind.
Do you understand
the instrument? Is
the instrument set
correctly?
Remove Rust !