KYMCO Super 8 50 Service Manual

Name: KYMCO Super 8 50
Brand: KYMCO
Rating: 5 (1 reviews)

185 pages

To Next Page

To Previous Page

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

Table of Contents1
Super2
Engine Serial Number2
General Information2
Specifications3
Service Precautions4
- Symbols11
- Standard Torque Values12
- Frame12
Torque Values12
Special Tools13
Lubrication Points14
Cable & Harness Routing16
Wiring Diagram19
- Engine will Not Start or Is Hard to Start20
- Troubleshooting20
- Engine Lacks Power21
- Poor Performance at Low and Idle Speed23
- Poor Performance at High Speed24
- Poor Handling24
- Schematic Drawing25
- Frame Covers/Exhaust Muffler26
- Service Information28
- General Instructions28
- Items Related for Removal28
Frame Covers/Exhaust Muffler28
- Frame Covers29
- Front Cover Removal29
- Handlebar Front Cover Removal29
- Handlebar Rear Cover Removal29
- Frame Body Cover Removal30
- Floor Board Removal32
- Front Fender and under Cowl Removal32
- Exhaust Muffler Removal33
- Inspection/Adjustment34
- Tire Pressure35
- Tire Size35
- Fuel Filter36
- Maintenance Schedule36
- Throttle Operation37
- Air Cleaner38
  - Air Cleaner Replacement38
  - Change Interval38
- Spark Plug38
- Valve Clearance39
- Cylinder Compression40
- Ignition Timing40
Inspection/Adjustment40
- Valve Clearance40
- Drive Belt41
- Final Reduction Gear Oil41
  - Oil Change41
  - Oil Level Check41
- Super 841
- Clutch Shoe Wear42
- Headlight Aim42
  - Rear Suspension42
  - Suspension Front42
- Nuts/Bolts/Fasteners43
- Steering Handlebar43
- Wheels/Tires43
Lubrication System44
- Lubrication System45
  - Oil Level too Low45
  - Poor Lubrication Pressure45
- Service Information45
- Troubleshooting45
- Engine Oil/Oil Filter46
  - Oil Level46
  - Oil Pump Removal46
  - Fuel Injection System51
- System Diagram52
- Parts Location53
- Service Information54
  - Backfiring or Misfiring During Acceleration55
  - Engine Stall, Hard to Start, Rough Idling55
  - Engine Won’t Start55
  - Poor Performance (Drive Ability) and Poor Fuel Economy55
- Troubleshooting55
- Check Engine Lamp (Celp)56
- How to Show the Failure Code57
  - Failure Code Chart58
  - Failure Code59
- Ecu62
- Voltage Inspection62
- Fuel Pump63
  - Enter the Data Analyze64
  - T-MAP Sensor64
  - TPS (Throttle Position Sensor)64
  - ETS (Engine Temperature Sensor)65
- Injector65
- Wts65
- O2 Sensor66
- Roll Sensor67
- Tp Screw67
- TPI / ABV Initialization68
- Diagnostic Report69
- Fi Diagnostic Tool70
- Dtc Inspection71
- Dtc Clear Procedure74
- Data Analysis75
- Adjust77
- Engine Removal/Installation78
Engine Removal/Installation80
- Engine Hanger Bracket Installation82
- Engine Installation82
Cylinder Head/Valves83
- Compression too High85
- White Smoke from Exhaust Muffler85
- Compression too Low85
- Poor Performance at Idle Speed85
- Camshaft Removal86
- Camshaft Holder Disassembly88
- Camshaft Holder Inspection88
- Cylinder Head Remove89
- Cylinder Head Disassembly90
- Valve Spring Compressor90
- Cylinder Head Inspection90
- Valve Spring Free Length90
- Valve /Valve Guide91
- Cylinder Head Assembly91
- Camshaft Holder Assembly92
- Cylinder Head Installation92
- Camshaft Installation93
Cylinder/Piston95
- Compression too Low or Uneven Compression96
- Excessive Smoke from Exhaust Muffler96
- Abnormal Noisy Piston96
- Cylinder Removal97
- Piston Removal97
- Cylinder Inspection99
- Piston Ring Installation100
- Piston Installation101
- Cylinder Installation101
Drive and Driven Pulleys103
- Lack of Power104
- Engine Starts but Motorcycle Won‘t Move104
- Engine Stalls or Motorcycle Creeps104
- Left Crankcase Cover105
- Drive Pulley106
- Clutch/Driven Pulley110
- Clutch Spring Compressor111
- Driven Pulley Face Bearing113
- Clutch Disassembly114
- Clutch Assembly114
- Clutch/Driven Pulley Assembly114
Final Reduction117
- Abnormal Noise118
- Oil Leaks118
- Final Reduction Disassembly119
- Final Reduction Inspection119
- Bearing Replacement120
- Bearing Puller121
- Final Reduction Assembly121
Crankcase/Crankshaft123
- Excessive Engine Noise124
- Crankcase Separation125
- Crankshaft Inspection126
- Crankcase Assembly127
Front Wheel/Front Brake/ Front Suspension129
- Front Shock Absorber Noise131
- Soft Front Shock Absorber131
- Front Wheel Wobbling131
- Hard Steering (Heavy)131
- Steering Handlebar132
- Front Wheel133
- Wheel Rim134
- Hydraulic Brake (Front Brake)136
- Brake Fluid Replacement/Air Bleeding136
- Brake Fluid Bleeding136
- Brake Fluid Refilling136
- Brake Pad/Disk Replacement137
- Brake Disk137
- Brake Master Cylinder138
- Brake Caliper (Front)141
- Front Shock Absorber144
- Front Fork147
- Long Socket Wrench,32Mm 8Angle147
- Bottom Cone Race Replacement147
- Ball Race Replacement147
Rear Wheel/Rear Brake/Rear149
- Rear Shock Absorber Removal151
- Rear Wheel Removal151
- Rear Brake Removal152
- Brake Lining Inspection152
- Rear Brake Disassembly152
- Rear Brake Assembly152
- Battery/Charging System/A.C Generator154
- No Power156
- Low Power156
- Intermittent Power156
- Charging System Failure156
- Battery Voltage (Open Circuit Voltage) Inspection157
- Short Circuit Test158
- Current Test158
- Regulator/Rectifier159
- Main Harness Circuit Inspection159
- A.C. Generator Charging Coil160
- A.C. Generator160
- A.C. Gnerator Installation162
Ignition System165
- No Peak Voltage167
- Peak Voltage Is Normal, but no Spark Jumps at the Plug167
- Ignition Coil168
- Continuity Test168
- Pulser Coil169
- Ignition Timing Inspection169
- Timing Hole Cap169
- A .C. Generator Inspection170
- Crank Position Sensor Inspection170
- Angle Detect Sensot170
Starting System172
- Starter Motor Rotates but Engine Does Not Start173
- Starter Motor Won‘t Turn173
- Starter Motor Case Continuity Check175
- Starter Relay176
- Operation Test177
- Starter Clutch177
- Starter Relay Ground Circuit Inspection177
- Clutch Body Disassembly178
- Flywheel Holder178
- Starter Clutch Disassembly178
- Fuel Gauge Pointer Does Not Register Correctly180
- Light Dims180
- Troubleshooting180
- Fuel Unit181
Lights Do Not Come on When Ignition Switch Is “ON”180
Lights/Instruments/Switches180
- Fuel Gauge Inspection181
- Dimmer Switch182
- Handlebar Switches182
- Ignition Switch183
- Instruments184
- Stop Switch184
- Headlight185
- Bulb Replacement185

Other manuals for KYMCO Super 8 50

Owner's Manual56 pages

Questions and Answers:

Need help?

Do you have a question about the KYMCO Super 8 50 and is the answer not in the manual?

KYMCO Super 8 50 Specifications

General

Displacement	49.5 cc
Fuel System	Carburetor
Ignition	CDI
Front Suspension	Telescopic Fork
Front Brake	Disc
Rear Brake	Drum
Front Tire	120/70-12
Rear Tire	130/70-12
Cooling System	Air
Transmission	CVT Automatic
Seat Height	780 mm
Wheelbase	1, 280 mm

Related product manuals

KYMCO Super 8 50 Service Manual

Table of Contents

Other manuals for KYMCO Super 8 50

Questions and Answers:

KYMCO Super 8 50 Specifications

Related product manuals