Table Of Contents - KYMCO Super 8 50 Service Manual

Table of Contents

Table Of Contents1
General Information2
Engine Serial Number2
Super2
Specifications3
Service Precautions4
Symbols11
Torque Values12
Standard Torque Values12
Frame12
Special Tools13
Lubrication Points14
Cable & Harness Routing16
Wiring Diagram19
Troubleshooting20
Engine Will Not Start Or Is Hard To Start20
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 Covers29
Front Cover Removal29
Handlebar Rear Cover Removal29
Handlebar Front Cover Removal29
Frame Body Cover Removal30
Floor Board Removal32
Front Fender And Under Cowl Removal32
Exhaust Muffler Removal33
Inspection/Adjustment34
Tire Pressure35
Tire Size35
Maintenance Schedule36
Fuel Filter36
Throttle Operation37
Air Cleaner38
Air Cleaner Replacement38
Change Interval38
Spark Plug38
Valve Clearance39
Ignition Timing40
Cylinder Compression40
Final Reduction Gear Oil41
Oil Level Check41
Oil Change41
Drive Belt41
Super 841
Headlight Aim42
Clutch Shoe Wear42
Suspension Front42
Rear Suspension42
Nuts/Bolts/Fasteners43
Wheels/Tires43
Steering Handlebar43
Lubrication System44
Oil Level Too Low45
Poor Lubrication Pressure45
Oil Level46
Oil Pump Removal46
Engine Oil/Oil Filter46
Fuel Injection System51
System Diagram52
Parts Location53
Engine Won't Start55
Engine Stall, Hard To Start, Rough Idling55
Backfiring Or Misfiring During Acceleration55
Poor Performance (Drive Ability) And Poor Fuel Economy55
Check Engine Lamp (Celp)56
How To Show The Failure Code57
Failure Code Chart58
Failure Code59
Ecu62
Voltage Inspection62
Fuel Pump63
T-Map Sensor64
Tps (Throttle Position Sensor)64
Enter The Data Analyze64
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 Hanger Bracket Installation82
Engine Installation82
Cylinder Head/Valves83
Poor Performance At Idle Speed85
Compression Too Low85
Compression Too High85
White Smoke From Exhaust Muffler85
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
Cylinder Head Installation92
Camshaft Holder Assembly92
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
Engine Starts but Motorcycle Won't Move104
Engine Stalls Or Motorcycle Creeps104
Lack Of Power104
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
Hard Steering (Heavy)131
Front Wheel Wobbling131
Soft Front Shock Absorber131
Front Shock Absorber Noise131
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 Won't Turn173
Starter Motor Rotates But Engine Does Not Start173
Starter Motor Case Continuity Check175
Starter Relay176
Starter Relay Ground Circuit Inspection177
Operation Test177
Starter Clutch177
Flywheel Holder178
Starter Clutch Disassembly178
Clutch Body Disassembly178
Lights/Instruments/Switches180
Lights Do Not Come on When Ignition Switch Is "ON"180
Light Dims180
Fuel Gauge Pointer Does Not Register Correctly180
Fuel Unit181
Fuel Gauge Inspection181
Handlebar Switches182
Headlight Switch182
Starter Switch182
Dimmer Switch182
Horn Switch183
Switch Replacement183
Ignition Switch183
Ignition Switch Replacement183
Stop Switch184
Horn184
Instruments184
Headlight185
Bulb Replacement185