KYMCO SUPER8 50 User manual

1.SPECIFICATIONS
1-0
SUPER8 50 2T
1 TABLE OF CONTENTS
SPECIFICATIONS................................................................................ 1
GENERAL INFORMATION.................................................................. 2
INSPECTION/ADJUSTMENT .............................................................. 3
LUBRICATION SYSTEM ..................................................................... 4
ENGINE REMOVAL/INSTALLATION.................................................. 5
CYLINDER HEAD/CYLINDER/PISTON............................................... 6
A.C. GENERATOR............................................................................... 7
KICK STARTER/DRIVE PULLEY/CLUTCH/DRIVEN PULLEY........... 8
FINAL REDUCTION............................................................................. 9
CRANKCASE/CRANKSHAFT.............................................................10
CARBURETOR....................................................................................11
FRAME COVERS.................................................................................12
STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/
FRONT SHOCK ABSORBER/FRONT FORK .....................................13
REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER..............14
ELECTRICAL EQUIPMENT.................................................................15
INSTRUMENT/SWITCHES/LIGHTS....................................................16
EXHAUST EMISSION CONTROL SYSTEM........................................17

1.SPECIFICATIONS
1-1
SUPER8 50 2T
SPECIFICATIONS
Name & Model SUPER8 50 2T
Overall length (mm) 2040
Overall width (mm) 745
Overall height (mm) 1240
Wheel base (mm) 1350
Engine type Air cooled 2-stroke
Fuel Used 92# nonleaded
Displacement (cc) 49.5 cc
Front wheel 44
Net weight (kg) Rear wheel 63.5
Total 107.5
Front wheel 44
Gross weight(kg) Rear wheel 68
Total 112
Front wheel 120/70-14 50P
Tires Rear wheel 120/80-14 52P
Ground clearance (mm) 120
Braking distance (m)
(Initial speed Km/h) 4m (30km/h)
Min. turning radius (mm)R/L 2000/2000
Starting system Starting motor &
kick starter
Fuel type Gasoline, 2-stroke
motor oil
Cylinder arrangement Single cylinder, flat
Combustion chamber type Semi-sphere
Valve arrangement Reed valve & piston
Bore x stroke (mm) 39 x 41.4
Compression ratio 7.2:1 ±0.2
Compression pressure
(kg/cm²rpm) 11.8kg/cm²±2
Max. output (ps/r/min)
Speed limit/No limit 2.6/6500 2.8/6500
Max. torque (kg m/rpm) 0.42/6000 kg m/rpm
Open Automatic controlled
Intake Close Automatic controlled
Port Open ⎯
timing Exhaust Close ⎯
Open ⎯
Scaveng
eClose ⎯
Idle speed (rpm) 1850±100
Lubrication type Separate type
Oil pump type Plunger type
Oil filter type Full-flow filtration
Lubrication oil capacity (liter) 1.1
Air cleaner type & No. Wet, single
Fuel capacity (liter) 6.0
Type Plunger type
Carburetor Piston dia. (mm) ⎯
Venturi dia. (mm) 16
Ignition system type CDI electromagnetic
Ignition
Ignition timing F mark 13.5°±1°BTDC/2000
rpm
Spark
plug NGK BR8HSA
Spark plug gap (mm) 0.6～0.7
Battery capacity 12V6AH
Power to transmission gear Power-transmission
gear-clutch
Reduction ratio of power to
transmission ⎯
Clutch type Dry multi-disc clutch
Transmission gear operation
type Automatic centrifugal
type
Transmission ratio 1 speed ⎯
Reduction Type Two-stage reduction
gear 1st reduction ratio 3.113~0.895
2nd reduction ratio 14.69
Transmission gear type Non-stage
Tire
p
ressure Front wheel 1.75 kg/cm²
(kg/cm²)Rear wheel 2.25 kg/cm²
Turning angle Right & left 45°
Brake s
y
stem Front wheel hydraulic
type Rear wheel Expanding
Sus
p
ension Front wheel Telescope
type Rear wheel Unit swing
Shock absorber Front wheel Telescope
type Rear wheel Unit swing
Frame type Pipe under bone

2 . GENERAL INFORMATION
2-0
SUPER8 50 2T
2
________________________________________________________________________________
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GENERAL INFORMATION
________________________________________________________________________________
ENGINE SERIAL NUMBER/IDENTIFICATION....................................................2- 1
SERVICE PRECAUTIONS...................................................................................2- 2
SERVICE INFORMATION....................................................................................2- 10
TORQUE VALUES ...............................................................................................2- 12
SPECIAL TOOLS .................................................................................................2- 13
LUBRICATION POINTS .......................................................................................2- 15
WIRING DIAGRAM...............................................................................................2- 16
CABLE & HARNESS ROUTING...........................................................................2- 17
TROUBLESHOOTING..........................................................................................2- 21
2

2 . GENERAL INFORMATION
2-1
SUPER8 50 2T
ENGINE SERIAL NUMBER/IDENTIFICATION
Location of Engine Serial Numbe
r

2 . GENERAL INFORMATION
2-2
SUPER8 50 2T
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.

2 . GENERAL INFORMATION
2-3
SUPER8 50 2T
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.

2 . GENERAL INFORMATION
2-4
SUPER8 50 2T
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

2 . GENERAL INFORMATION
2-5
SUPER8 50 2T
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!

2 . GENERAL INFORMATION
2-6
SUPER8 50 2T
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 !

2 . GENERAL INFORMATION
2-7
SUPER8 50 2T
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 ti
g
ht!
Do not press o
r
s
q
ueeze the wire.

2 . GENERAL INFORMATION
2-8
SUPER8 50 2T
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 you understand
the instrument? Is
the instrument set
correctly?
Remove Rust !

2 . GENERAL INFORMATION
2-9
SUPER8 50 2T
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.
: Use special tool.
: Caution
: Warning
Engine Oil
Grease
Special
＊

2 . GENERAL INFORMATION
2-10
SUPER8 50 2T
SERVICE INFORMATION
ENGINE Standard (mm) Service Limit (mm)
Item SUPER8 50 2T SUPER8 50 2T
Cylinder head warpage ⎯0.10
Piston O.D.(5mm frombottom of pistonskirt) 38.970～38.955 38.90
Cylinder-to- piston clearance 0.10
Piston pin hole I.D. 12.002～12.008 12.03
Piston pin O.D. 11.994～12.0 11.98
Piston-to-piston pin clearance ←←
Piston ring end gap (top/second) 0.10～0.25 0.40
Connecting rod small end I.D. 17.005～17.017 17.03
Cylinder bore 39.0～39.025 39.05
Drive belt width 18 17
Drive pulley collar O.D. 20.01～20.025 ←
Movable drive face ID. 20.035～20.085 19.97
Weight roller O.D. 13.0 12.4
Clutch outer I.D. 107～107.2 107.5
Driven face spring free length 87.9 82.6
Driven face O.D. ←←
Movable driven face I.D. ←←
Connecting rod big end side clearance ←←
Connecting rod big end radial clearance ←←
Crankshaft runout A/B ⎯←
CARBURETOR SUPER8 50 2T
Venturi dia. 16mm
Identification number PB
Float level 8.6mm
Main jet #72
Slow jet #35
Air screw opening 1¼±½
Idle speed 1950±100rpm
Throttle grip free play 2～6mm
Jet needle clip notch 1st notch

2 .GENERALINFORMATION SUPER8 50 2T
2-11
FRAME Standard (mm) Service Limit (mm)
Item SUPER8 50 2T SUPER8 50 2T
Axle shaft runout ⎯0.2
Radial
Front wheel rim runout Axial
Front shock absorber spring free length 200.0 182.8
Rear wheel rim runout 2.0
Brake drum I.D. Front/rear 110 111
Brake lining thickness Front/rear 5.7/4.0 2.0/2.0
Brake disk runout Front/rear ⎯0.30
Rear shock absorber spring free length 235.7 218.7
ELECTRICAL EQUIPMENT SUPER8 50 2T
Capacity 12V6AH
Voltage 13.0～13.2V
Charging Standard 0.4A/5H
Battery
current Quick 4A/0.5H
Spark plug (NGK) BR8HSA
Spark plug gap 0.6～0.7mm
Primary coil 0.153～0.187Ω
Secondary coil
(with plug cap) 6.99～10.21KΩ
Ignition coil resistance Secondary coil
(without plug cap) 3.24～3.96KΩ
Pulser coil resistance (20℃)80～160Ω
Ignition timing 13°±1°BTDC/2000rpm

2 . GENERAL INFORMATION
2-12
SUPER8 50 2T
TORQUE VALUES
ENGINE
Item Thread dia. (mm) Torque (kg-m) Remarks
Cylinder head bolt
Clutch drive plate nut
Clutch outer nut
Drive face nut
Oil check bolt
Engine mounting bolt
Engine hanger bracket bolt
Exhaust muffler joint lock nut
Exhaust muffler lock bolt
Spark plug
BF7x115
10
NH10
NH12
10
BF10x95
BF10x50
M8mm
BF8x35
1.5～1.7
3.5～4.0
3.5～4.5
5.0～6.0
1.0～1.5
4.5～5.5
3.5～4.5
1.8～2.2
3.0～3.6
1.1～1.7
(cold)
(cold)
FRAME
Item Thread dia. (mm) Torque (kg-m) Remarks
Handlebar lock nut
Steering stem lock nut
Steering top cone race
Front axle nut
Rear axle nut
Rear brake arm bolt
Front shock absorber:
upper mount bolt
lower mount bolt
hex bolt
Front damper nut
Front pivot arm bolt
Rear shock absorber:
upper mount bolt
lower mount bolt
lower joint nut
10
25.4
25.4
12
16
8
8
10
8
8
4.5～5.0
7.0～8.0
0.5～1.3
5.0～7.0
11.0～13.0
2.4～3.0
1.5～3.0
1.5～3.0
3.5～4.5
2.4～3.0
1.8～2.2
Flange bolt/U-nut
Flange U-nut
Flange U-nut
Flange nut
Flange bolt/U-nut
Cross head
Apply locking agent
Flange screw/U-nut
Flange nut
Torque specifications listed above are for important fasteners. Others should be tightened to
standard torque values below.
STANDARD TORQUE VALUES SH bolt: 8mm Flange 6mm bolt
Item Torque (kg-m) Item Torque (kg-m)
5mmbolt,nut
6mmbolt,nut
8mmbolt,nut
10mm bolt, nut
12mm bolt, nut
0.45～0.6
0.8～1.2
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

2 .GENERALINFORMATION SUPER8 50 2T
2-13
SPECIAL TOOLS
Tool Name Tool No. Remarks
Universal bearing puller Crankshaft bearing removal
Lock nut wrench, 39mm Drive pulley disassembly/assembly
Lock nut socket wrench Top cone race holding
Lock nut wrench, Stem lock nut tightening
Crankcase puller Crankcase disassembly
Bearing remover set, 12mm
(Spindle assy, 15mm)
(Remover weight)
Drive shaft bearing removal/installation
Bearing remover set, 15mm
(Spindle assy, 15mm)
(Remover head, 15mm)
(Remover shaft, 15mm)
Drive shaft bearing removal/installation
Bearing outer driver, 28x30mm Bearing installation
Bearing remover Driven pulley outer bearing installation
Clutch spring compressor Driven pulley disassembly/assembly
Crankcase assembly collar Driven shaft, crankshaft & crankcase
assembly
Crankcase assembly tool Crankshaft & crankcase assembly
Rear shock absorber remover Front shock absorber disassembly/
assembly
Ball race remover Steering stem bearing races
Rear shock absorber compressor Rear shock absorber disassembly/assembly
Float level gauge Carburetor fuel level check
Lock nut socket wrench, 32mm One-way clutch lock nut removal/
installation
Universal holder Flywheel holding
Flywheel puller Flywheel removal
Pilot, 12mm Drive shaft bearing installation
Bearing outer driver, 32x35mm Drive shaft bearing installation
Final shaft bearing installation

2 . GENERAL INFORMATION
2-14
SUPER8 50 2T
Tool Name Tool No. Remarks
Bearing outer driver, 37x40mm Drive shaft bearing installation Final shaft bearing installation Crankshaft bearing
installation
Outer driver, 24x26mm Driven pulley bearing installation
Pilot, 10mm Front wheel bearing installation
Bearing driver pilot, 17mm Drive shaft bearing installation
Snap ring pliers (close) Circlip removal/installation
Bearing outer driver, 42x47mm Crankshaft bearing installation
Pilot, 20mm Crankshaft bearing installation
Bearing outer driver handle A Bearing installation
Drive in ball race
Bearing puller head, 10mm Front wheel bearing removal
Universal bearing puller Crankshaft bearing removal
Bearing puller Front wheel bearing removal
Pressure tester set Cylinder compression gauge

2 .GENERALINFORMATION SUPER8 50 2T
2-15
LUBRICATION POINTS
ENGINE
NO. Lubrication Points Lubricant Remarks
1 Crankcase sliding & movable JASO-FC or API-TC
2 Cylinder movable parts
3 Transmission gear (final gear) SAE-90#
4 Kick starter spindle bushing Grease
5 Drive pulley movable parts Grease
6 Starter pinion movable parts Grease
FRAME
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.
Front/Rear Brake Leve
r
Seat Lock
Rear Wheel
Bearing
Throttle Cable
Main Stand Pivot
Grease
Engine Oil
Grease
Speedometer Gear/
Brake Cam/Front
Shock Absorber
Lower Mount
Bushings/Pivot
Grease
Grease
Grease
Grease
Engine Oil
Rear Brake Cable
Brake Cam/
Anchor Pin

2 . GENERAL INFORMATION
2-16
SUPER8 50 2T
PEOPLE S 50 WIRING DIAGRAM

2 .GENERALINFORMATION SUPER8 50 2T
2-17
CABLE & HARNESS ROUTING
Front Brake Reservoi
r
Rear Brake Cable
Throttle Cable
Front Stop Brake
Rear Stop Brake
Front Brake Fluid
Tube
Speedometer Cable
Horn
Regulator/Rectifie
r