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 !

1. GENERAL INFORMATION
1-10
SUPER 8 50
Symbols:
The following symbols represent the
servicing methods and cautions included in
this service manual.
: Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
: Apply grease for lubrication.
: Transmission Gear Oil (90#)
: Use special tool.
: Caution
: Warning
(12-3) :Refer to page 12-3.
Engine Oil
Grease
Gear Oil
Special
＊

1. GENERAL INFORMATION
1-11
SUPER 8 50
TORQUE VALUES
STANDARD TORQUE VALUES
Item
Torque (kg-m)
Item
Torque (kg-m)
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
0.45-0.6
0.6-1.2
1.8-2.5
3.0-4.0
5.0-6.0
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
0.35-0.5
0.7-1.1
1.0-1.4
2.4-3.0
3.5-4.5
Torque specifications listed below are for important fasteners.
ENGINE
Item
Q‘ty
Thread dia.(mm)
Torque (kg-m)
Remarks
Cylinder head bolt A
Cylinder head bolt B
Oil filter screen cap
Exhaust muffler lock bolt
Cylinder head flange nut
Valve adjusting lock nut
Cam chain tensioner slipper bolt
Oil bolt
Clutch outer nut
Clutch drive plate nut
Starter motor mounting bolt
Oil pump bolt
Drive face nut
Spark plug
A.C. generator stator bolt
Cam chain tensioner bolt
2
4
1
2
4
2
1
1
1
1
2
3
1
1
2
1
6
6
30
6
7
3
8
8
10
28
6
4
10
10
6
6
0.7-1.1
0.7-1.1
1.0-2.0
0.7-1.1
1.2-1.6
0.07-0.09
0.4-0.7
1.1-1.5
3.5-4.5
5.0-6.0
0.8-1.2
0.1-0.3
5.5-6.5
1.0-1.4
0.8-1.2
0.8-1.2
Double end bolt
Double end bolt
Apply oil to
threads
FRAME
Item
Q‘ty
Thread dia.(mm)
Torque (kg-m)
Remarks
Steering stem lock nut
Front axle nut
Rear axle nut
Rear shock absorber upper bolt
Rearshock absorberlowerbolt
Speedometer cable set screw
Rear shock absorber lock nut
1
1
1
1
1
1
1
25.4
10
14
10
8
5
8
8.0-12.0
5.0-7.0
11.0-13.0
4.0-5.0
2.0-3.0
0.45-0.6
3.0-3.6
U-nut
U-nut
U-nut
Applylockingagent

1. GENERAL INFORMATION
1-12
SUPER 8 50
SPECIAL TOOLS
Tool Name
Tool No.
Remarks
Ref. Page
Bearing puller 10.12.15.18 mm
E037
10.12.15.18mm bearing
10-3
10-4
12-6
Bushing remover L
E032
11102 bush engine hanger rubber
Bushing remover S
EO19
11203 bush rear cushion under rubber
Crankshaft bearing puller
E030
91005 radial bearing
Crankshaft protector
E029
13000 crankshaft comp 12mm.14mm
Clutch spring compressor
E027
2301a driven pully assy
9-9
9-12
Cushion assemble & disassemble
tool
F004
52400 cushion assy
13-4
Flywheel holder
E017
31110 flywheel comp.2310a pully assy
driven
9-5
9-9
9-13
14-7
14-9
Flywheel puller
E002
Left hand thread 27mm
14-7
Long socket wrench 32mm 8angle
F002
50306 steering stem
12-21
12-22
Oil seal & bearing installer
E014
Oil seal & bearing install
Tool boox
E033
Special tools storage
Tappet adjuster
E036
90012 screw tappet
3-5
Valve spring compressor
E038
Valve spring
7-7
7-8

1. GENERAL INFORMATION
1-13
SUPER 8 50
LUBRICATION POINTS
ENGINE
Lubrication Points
Lubricant
Valve guide/valve stem movable part
Cam lobes
Valve rocker arm friction surface
Cam chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundings
Cylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft R/L side oil seal
Starter reduction gear engaging part
Countershaft gear engaging part
Final gear engaging part
Bearing movable part
O-ring face
Oil seal lip
Genuine KYMCO Engine Oil (SAE15W-40)
APISG Engine Oil
Starter idle gear
Friction spring movable part/shaft movable part
Shaft movable grooved part
Kick starter spindle movable part
High-temperature resistant grease
A.C. generator connector
Transmission case breather tube
Adhesive

1. GENERAL INFORMATION
1-14
SUPER 8 50
FRAME
The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified.
This will avoid abnormal noise and rise the durability of the motorcycle.
Rear Wheel Bearings
Main Stand Pivot
Speedometer Gear/ Front Wheel
Bearings/ Brake Cam/ Anchor Pin
/Front Shock Absorber Lower
Mount Bushings/Pivot
Grease
Grease
Grease
Engine Oil
Rear Brake Cable
Brake Cam/
Anchor Pin
Grease
Grease
Front Brake Lever
Pivot
Front Brake Cable/
Speedometer Cable/
Throttle Cable
Engine/ Oil

1. GENERAL INFORMATION
1-15
SUPER 8 50
CABLE & HARNESS ROUTING
Throttle Cable
Front brake tube
Fuel Pump Realy
Horn
Ignition Switch
Low Beam realy
Roll Sensor
Speedometer
High Beam realy

1. GENERAL INFORMATION
1-16
SUPER 8 50
Battery (+) Cable
Battery (-) Cable
Fuel Pump
Fuel Level Indicator
Fuel Tube
Fuse

1. GENERAL INFORMATION
1-17
SUPER 8 50
Throttle Cable
Fuel Tube
Crankcase Breather Tube
Ignition Coil
Starter Relay
Fuel Injector
O₂Sensor
ECU
CPS

1. GENERAL INFORMATION
1-18
SUPER 8 50
WIRING DIAGRAM

1. GENERAL INFORMATION
1-19
SUPER 8 50
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Possible cause
1. Check for operation of the fuel pump Abnormal Faulty fuel pump
Normal
2. Inspect the fuel flow Abnormal Faulty pressure regulator
Normal
3. Inspect the fuel injector Abnormal Faulty injector
Normal
4. Perform spark test Weak or no spark Faulty spark plug
Fouled spark plug
Faulty ECU
Good spark Broken or shorted spark plug wire
Faulty ignition switch
Faulty ignition pulse generator
Loose or disconnected spark plug
wire
5. Test cylinder compression Low compression Valve stuck open
Worn cylinder and piston ring
Damaged cylinder head gasket
Compression normal Seized valve
Improper valve timing
6. Starting following normal procedure Engine start Intake pipe leaking
but stops Improper ignition timing (Faulty
ignition coil or ignition pulse
generator)
Engine does not start Fuel contaminated
7. Remove and inspect spark plug Wet plug Throttle valve open
Clogged air cleaner