KYMCO SUPER8 50 User manual

S
UPER8 50
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO SUPER8 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
FUEL SYSTEM 5
ENGINE REMOVAL/INSTALLATION 6
CYLINDER HEAD/VALVES 7
CYLINDER/PISTON 8
ENGINE
DRIVE AND DRIVEN PULLEYS/KIC
K
STARTER
9
FINAL REDUCTION 10
CRANKCASE/CRANKSHAFT 11
FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12
CHASSIS
REAR WHEEL /REAR BRAKE /REAR
SUSPENSION
13
BATTERY/CHARGING SYSTEM/A.C.
GENERATOR
14
IGNITION SYSTEM 15
STARTING SYSTEM 16
LIGHTS/INSTRUMENTS/SWITCHES 17
ELECTRICAL EQUIPMEN
T
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
SUPER8 50
Location of Engine Serial Numbe
r
Frame Serial Numbe
r
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
SUPER8 50
SPECIFICATIONS
Motorcycle Name & Type SUPER8 50
Name & Model No. LEJ2
Overall length (mm) 1940
Overall width (mm) 745
Overall height (mm) 1220
Wheel base (mm) 1365
Engine type O.H.C.
Displacement 50cc
Fuel Used 92# nonleaded gasoline
Front wheel 43
Net weight (kg) Rear wheel 55
Total 108
Front wheel 45
Gross weight(kg) Rear wheel 67
Total 144
Front wheel 100/80 -14 56J
Tires Rear wheel 120/80 -14 56J
Ground clearance (mm) 112
Perform- Braking distance (m) 4 (Initial speed
20km/h)
ance Min. turning radius (m) 1.99
Starting system Starting motor &
kick starter
Type Gasoline, 4-stroke
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement O.H.C.
Bore x stroke (mm) φ39.0 x 41.4
Compression ratio 11
Compression pressure
(kg/cm²-rpm) 18
Max. output 2.4/7500kw/(r/min)
Max. torque 3.2/7000kg m/rpm
Open 3°
Port Intake Close 7°
Engine
timin
g
Open 9°
Exhaust Close 1°
Valve
clearance Intake 0.08
(cold) (mm) Exhaust 0.08
Idle speed (rpm) 1900±100rpm
Lubrication type Forced
p
ressure &
wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Lubrication System
Oil capacity 0.8 liter
Cooling Type Forced air cooling
Air cleaner type & No Paper element, wet
Fuel capacity 6.0 liter
Type CVK
Piston dia. (mm) 18
Venturi dia.(mm) φ18.5equivalent
Carburetor
Throttle type Butterfly type
Type CDI
Ignition timing BTDC28°/4000rpm
Contact breaker Non-contact point type
Spark plug NGK CR7HSA
Spark plug gap 0.6～0.7mm
Battery Capacity 12V7AH
Clutch Type Dry multi-disc clutch
Type Non-stage transmission
Operation Automatic centrifugal
type
Type Two-stage reduction
Reduction 1st 0.8-3.1
ratio 2nd 11.05
Front Caster angle 27°
Axle Trail length ⎯
Tire
p
ressure Fron
t
1.75
(kg/cm²)Rear 2.25
Turning Left 45°
angle Right 45°
Fron
t
DISK
(
180mm
)
brake
Brake system
type Rear Drum (110mm) brake
Fron
t
TELESCOPE
Suspension type Rear Unit Swing
Front 80
Shock absorber
distance Rear 82
Frame type Under Bone
Fuel S
y
stem Electrical Equipment
I
g
nition S
y
stem
Power Drive System
Transmis- sion Gear Reduction
Gear
Moving Device Damping
Device

1. GENERAL INFORMATION
1-3
SUPER8 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
SUPER8 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
SUPER8 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.
Confir
m
Capacity

1. GENERAL INFORMATION
1-6
SUPER8 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.
Sna
pp
in
g
!

1. GENERAL INFORMATION
1-7
SUPER8 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.
N
o Contact !

1. GENERAL INFORMATION
1-8
SUPER8 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 ti
g
ht!
Do not press o
r
s
q
ueeze the wire.

1. GENERAL INFORMATION
1-9
SUPER8 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
SUPER8 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
(Ö12-3) :Refer to page 12-3.
Engine Oil
Grease
Gear Oil
Special
＊

1. GENERAL INFORMATION
1-11
SUPER8 50
TORQUE VALUES
STANDARD TORQUE VALUES
Ite
m
Tor
q
ue
(
k
g
-m
)
Ite
m
Tor
q
ue
(
k
g
-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
Rear shock absorber lower bolt
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
Apply locking agent

1. GENERAL INFORMATION
1-12
SUPER8 50
SPECIAL TOOLS
Tool Name Tool No. Remarks Ref. Page
10-3
10-4Bearing puller 10.12.15.18 mm E037 10.12.15.18mm bearing 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 fl
y
wheel com
p
.2310a
p
ull
y
ass
y
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
7-7
Valve spring compressor E038 Valve spring 7-8

1. GENERAL INFORMATION
1-13
SUPER8 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
SUPER8 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 Leve
r
Pivot
Front Brake Cable
/
Speedometer Cable/
Throttle Cable
Engine/ Oil

1. GENERAL INFORMATION
1-15
SUPER8 50
CABLE & HARNESS ROUTING
Front Stop Switch Wire Rear Stop Switch Wire
Throttle Cable
Regulator/Rectifie
r
Rear Brake Cable
Speedometer Cable
Horn
Ignition Switch
Winke
r
Front Brake Fluid Tube
Brake Master Cylinde
r

1. GENERAL INFORMATION
1-16
SUPER8 50
Regulator/Rectifie
r
Speedometer Cable
Ignition Switch
Throttle Grip
Rear Brake Leve
r
Front Brake Fluid Tube
Headlight Resisto
r
Horn
Control Lighting

1. GENERAL INFORMATION
1-17
SUPER8 50
Starter Relay
Fuse
Battery (+) Cable
Battery (-) Cable
CDI Unit
Fuel Tan
k
Ignition Coil

1. GENERAL INFORMATION
1-18
SUPER8 50
Throttle Cable Vacuum Tee
Carbureto
r
Overflow Tube
Fuel Tube
Crankcase Breathe
r
Tube
Ignition Coil
Primary Wire
Ignition Wire
Fuel Filte
r
Auto Cock Assy Fuel

1. GENERAL INFORMATION
1-19
SUPER8 50
Throttle Cable
Fuel Tube
Vacuum Tube
Auto Bystarte
r
Crankcase Breathe
r
Tube
Wire
Crankcase Breathe
r
Tube
Throttle Cable
Vacuum Tube
Fuel Unit
Reed Valve
Secondary Ai
r
Inlet Tube
Air Injection
Cut-off
Valve
Ignition Coil