KYMCO Super 8 50 Service Manual

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

185 pages

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2. FRAME COVERS/EXHAUST MUFFLER

2-0

NEW SUPER8 50

2 SCHEMATIC DRAWING

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

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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

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KYMCO Super 8 50 Service Manual

Table of Contents

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KYMCO Super 8 50 Specifications

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