KYMCO SUPER8 50 Manuals

Manuals and User Guides for KYMCO SUPER8 50. We have 2 KYMCO SUPER8 50 manuals available for free PDF download: Service Manual

KYMCO SUPER8 50 Service Manual

KYMCO SUPER8 50 Service Manual (189 pages)

Brand: KYMCO | Category: Scooter | Size: 11.79 MB

Table of Contents

Table of Contents
1
Specifications
2
General Information
7
- Symbols
  12
- Service Information
  13
- Standard Torque Values
  15
- Torque Values
  15
- Special Tools
  16
- Frame
  18
- Lubrication Points
  18
- People S 50 Wiring Diagram
  19
- Cable & Harness Routing
  20
- Troubleshooting
  24
- Engine will Not Start or Is Hard to Start
  24
- Engine Stops Immediately after It Starts
  25
- Engine Lacks Power
  27
- Poor Performance (Especially at Idle and Low Speeds)
  28
- Poor Performance (at High Speed)
  29
- Clutch, Drive and Driven Pulleys
  30
- Poor Brake Performance
  31
- Poor Suspension Performance
  31
- Oil Meter
  32
- Fuel Gauge
  33
- Pointer Does Not Register Correctly (Ignition Switch ON)
  33
- Pointer Fluctuates or Swings (Ignition Switch ON)
  33
- Starter Motor
  34
- Starter Motor Won‘t Turn
  34
- Starter Motor Turns Slowly or Idles
  34
- Starter Motor Does Not Stop Turning
  34
Inspection/Adjustment
35
- Inspection and Maintenance Schedule
  36
- Brake Lever
  39
- Brake System
  39
  - Brake Disk/Lining
    40
  - Brake Drum/Shoe
    40
  - Brake Fluid Level Inspection
    40
- Moving Device
  41
- Damping Device
  42
- Power Drive System
  42
  - Shock Absorbers
    42
  - Transmission Case
    42
- Electrical Equipment
  43
- Spark Plug
  43
- Engine
  44
- Ignition Apparatus
  43
- Body
  44
- At High and Low Speeds
  44
- Air Cleaner
  44
Lubrication System
45
- Cylinder Compression
  45
- Oil Filter Cleaning
  45
- Oil Pump Condition
  46
- Headlight
  47
- Lights
  47
- Others
  47
- Throttle Grip Free Play
  47
- Fuel System
  47
Lubrication System
49
- Engine Overheating
  50
- General Instructions
  50
- Oil Not Flowing out of Tank to Engine
  50
- Seized Piston
  50
- Service Information
  50
- Troubleshooting
  50
- Oil Pump Inspection
  51
- Oil Pump Removal
  51
- Oil Pump Installation
  52
- Oil Pump Bleeding
  53
- Oil Inlet Line/Oil Pump Bleeding
  53
- Oil Outlet Line Bleeding
  53
- Oil Tank Removal
  54
- Engine Removal/Installation
  55
Engine Removal/Installation
56
- Engine Removal
  57
- Engine Hanger Bracket Removal
  58
- Engine Hanger Bracket Inspection
  59
- Engine Installation
  59
- Cylinder Head/Cylinder/Piston
  60
- Abnormal Noisy Piston
  62
- Abnormal Noisy Piston Rings
  62
- Compression too High, Overheating or Knocking
  62
- Compression too Low, Hard Starting or Poor Performance at Low Speed
  62
- Service Information
  62
- Troubleshooting
  62
- Cylinder Head Removal
  63
- Combustion Chamber Decabonizing
  64
- Cylinder Head Inspection
  64
- Cylinder Head Installation
  64
- Cylinder Head Bolts Installation
  65
- Engine Hood Installation
  65
- Piston Removal
  66
- Cylinder Removal
  66
- Cylinder/Piston
  66
- Cylinder/Piston Inspection
  67
- Piston Ring Inspection
  69
- Connecting Rod Small End Inspection
  69
- Piston/Cylinder Installation
  69
A.C. Generator
71
- A.C. Generator Removal
  74
- A.C. Generator Installation
  75
Kick Starter/Drive Pulley/Clutch/Driven Pulley
77
- Engine Stalls or Motorcycle Creeps
  79
- Engine Starts but Motorcycle Won‘t Move
  79
- Poor Performance at High Speed or Lack of Power
  79
- Service Information
  79
- Troubleshooting
  79
- Kick Starter
  80
- Drive Pulley
  84
- Clutch/Driven Pulley
  85
  - Drive Belt Installation
    85
  - Drive Pulley Removal
    86
  - Movable Drive Face Disassembly
    86
  - Drive Pulley Installation
    87
  - Movable Drive Face Inspection
    87
  - Starter Pinion Inspection
    88
  - Starter Pinion Installation
    88
  - Starter Pinion Removal
    88
  - Clutch/Driven Pulley Disassembly
    89
  - Clutch/Driven Pulley Removal
    89
  - Clutch/Driven Pulley Inspection
    90
  - Driven Pulley Face Bearing Replacement
    92
  - Clutch/Driven Pulley Assembly
    93
  - Clutch/Driven Pulley Installation
    94
  - Final Reduction
    95
  - Abnormal Noise
    97
  - Oil Leaks
    97
- Service Information
  97
- Troubleshooting
  97
- Final Reduction Disassembly
  98
- Final Reduction Inspection
  98
- Bearing Replacement
  100
- Final Reduction Assembly
  101
- Crankcase/Crankshaft
  104
- Abnormal Engine Noise
  106
Crankcase/Crankshaft
106
- Service Information
  106
- Troubleshooting
  106
- Crankcase Separation
  107
- Crankshaft Removal
  107
- Crankshaft Inspection
  108
- Crankshaft Installation
  109
- Crankcase Assembly
  111
- Carburetor
  113
- Lean Mixture
  115
- Rich Mixture
  115
- Engine Idles Roughly, Stalls or Runs Poorly
  115
- Engine Does Not Start
  115
Carburetor
115
- Service Information
  115
- Troubleshooting
  115
- Throttle Valve Disassembly
  116
- Throttle Valve Installation
  117
- Carburetor Removal
  118
  - Auto Bystarter Inspection
    119
  - Auto Bystarter Removal
    120
  - Auto Bystarter Installation
    121
- Float Chamber
  121
  - Carburetor Passages Cleaning
    122
  - Float/Float Valve Inspection
    122
  - Jets/Screws Removal
    122
  - Float Chamber Assembly
    123
- Float Level Inspection
  123
- Air Screw Adjustment
  124
- Carburetor Installation
  124
- Reed Valve Removal
  125
- Reed Valve Inspection
  125
- Reed Valve Installation
  125
- Fuel Tank Assembly
  126
- Fuel Tank Removal
  126
- Frame Covers
  127
- Assembly Drawing
  128
- Items Related for Removal
  129
Frame Covers
129
- Frame Covers Removal
  130
- Rear Carrier
  130
- Frame Body Cover Removal
  130
- Floor-Foot Removal
  131
- Leg Shield Low Removal
  132
- Front Upper Cover Removal
  132
- Windshield Removal
  133
- Handlebar Cover Removal
  133
- Bottom Cover Removal
  134
- Front Fender and under Cowl Removal
  134
- Exhaust Muffler Removal
  135
- Front Wheel/Front Brake/Front Suspension
  136
Steering Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Front Fork
138
- Service Information
  138
- Troubleshooting
  139
  - Axle Runout
    140
  - Front Wheel Inspection
    140
  - Front Wheel Removal
    140
  - Wheel Rim
    140
  - Front Wheel Bearing
    141
- Hydraulic Brake Drawing
  143
  - Brake Fluid Bleeding
    144
  - Brake Fluid Refilling
    144
  - Brake Fluid Replacement/Air Bleeding
    144
  - Hydraulic Brake (Front Brake)
    144
  - Brake Disk
    145
  - Brake Master Cylinder Disassembly
    145
  - Brake Master Cylinder Removal
    145
  - Brake Caliper (Front) Disassembly
    147
  - Brake Caliper (Front) Removal
    147
  - Front Shock Absorber Removal
    149
- Steering Handlebar
  149
- Steering Handlebar Removal
  150
- Steering Stem Removal
  151
- Bottom Cone Race Replacement
  152
- Ball Race Replacement
  152
- Handlebar Installation
  153
- Rear Wheel/Rear Brake/Rear Shock Absorber
  154
- Rear Wheel Removal
  157
- Rear Wheel Inspection
  157
- Rear Wheel Installation
  157
- Shock Absorber
  157
- Rear Brake Disassembly
  158
- Brake Lining Inspection
  158
- Rear Brake
  158
Rear Wheel/Rear Brake/Rear Shock Absorber
159
- Rear Shock Absorber Removal
  160
- Rear Shock Absorber Installation
  160
- No Power
  162
- Low Power
  162
- Intermittent Power
  162
- Charging System Failure
  162
Electrical Equipment
162
- No Spark at Plug
  163
- Engine Starts but Turns Poorly
  163
- Lack of Power
  163
- Starter Motor Rotates but Engine Does Not Start
  163
- Charging Method
  165
- Battery Charging (Open Circuit Voltage) Inspection
  165
- Battery Removal
  165
- Performance Test
  166
- A.C. Generator (Charging Coil) Inspection
  166
- Resistor Inspection
  167
- Regulator/Rectifier Inspection
  167
- Ignition Coil Inspection
  169
- Exciter Coil/Pulser Coil Inspection
  170
- CDI Unit Inspection
  171
- CDI Circuit Inspection
  171
- Starter Relay Inspection
  173
- Starter Motor Removal
  173
- Starter Motor Inspection
  174
- Headlight Does Not Change When Dimmer Switch Is Turn to Hi or lo
  176
- Light Dims
  176
- Lights Do Not Come on When Ignition Switch Is “ON”
  176
Instrument/Switches/Lights
176
- Fuel Gauge Inspection
  177
- Fuel Gauge Installation
  178
- Oil Meter Inspection
  178
- Oil Meter Operation Inspection
  178
- Ignition Switch Inspection
  179
- Ignition Switch Replacement
  179
- Switches
  179
- Dimmer Switch Inspection
  180
- Turn Signal Switch Inspection
  180
- Horn Switch Inspection
  181
- Starter Switch Inspection
  181
- Stop Switch Inspection
  181
- Front Turn Signal Light Replacement
  182
- Horn Inspection
  182
- Taillight/Stoplight/Rear Turn Signal Light Bulb Replacement
  182
- Bulb Replacement
  183
- Headlight Removal/Bulb Replacement
  183
- Instruments
  183
- Instruments Replacement
  183
- Exhaust Emission Control System
  184
- Exhaust Emission Control System Function
  185
- Exhaust Emission Control System Schematic Drawing
  185
- Secondary Air Cleaner
  185
- Air Injection Cut-Off Valve (A.I.C.V.)
  186
  - Backfiring at Sudden Deceleration
    186
  - Exhaust Muffler Noise
    186
  - High CO at Idle Speed
    186
- Secondary Air Cleaner / Air Injection Control Valve (A.I.C.V.)
  187
- Reed Valve
  188

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KYMCO SUPER8 50 Service Manual

KYMCO SUPER8 50 Service Manual (99 pages)

Brand: KYMCO | Category: Scooter | Size: 12.78 MB

Table of Contents

Preface

1
- Table of Contents
  1
- Engine Serial Number
  2
- General Information
  2
- Specifications
  3
- Service Precautions
  4
- Torque Values
  12
- Special Tools
  13
- Lubrication Points
  14
- Cable & Harness Routing
  16
- Wiring Diagram
  21
  - Frame Covers/Exhaust Muffler
    28
- Frame Covers/Exhaust Muffler
  29
3. Inspection/Adjustment 3

35
- Inspection/Adjustment
  35
  - Maintenance Schedule
    37
  - Fuel Filter
    38
  - Throttle Operation
    38
  - Air Cleaner
    39
  - Spark Plug
    39
  - Valve Clearance
    40
  - Carburetor Idle Speed
    40
  - Ignition Timing
    41
  - Cylinder Compression
    41
  - Final Reduction Gear Oil
    42
  - Drive Belt
    42
  - Brake Fluid
    43
  - Brake Shoe
    43
  - Brake Adjusting Nut
    43
  - Headlight Aim
    44
  - Clutch Shoe Wear
    44
  - Suspension
    44
  - Nuts/Bolts/Fasteners
    45
  - Wheels/Tires
    45
  - Lubrication System
    47
- Lubrication System
  48
- Service Information
  48
  - Engine Oil/Oil Filter
    49
  - Oil Pump
    50
  - Fuel System
    54
5. Fuel System

56
- Fuel System
  56
  - Troubleshooting
    57
  - Carburetor Removal
    58
  - Auto Bystarter
    58
  - Air Cut-Off Valve
    60
  - Vacuum Chamber
    60
  - Float Chamber
    62
  - Accelerating Pump
    64
  - Carburetor Installation
    65
  - Pilot Screw Adjustment
    66
  - Fuel Tank
    67
  - Fuel Unit
    68
  - Air Cleaner
    68
- Engine Removal/Installation
  72
  - Engine Installation
    74
  - Cylinder Head/Valves
    76
7. Cylinder Head/Valves

77
- Cylinder Head/Valves
  77
- Troubleshooting
  78
- Camshaft Removal
  79
- Cylinder Head Removal
  81
- Cylinder Head Disassembly
  83
- Cylinder Head Assembly
  84
- Cylinder Head Installation
  84
- Camshaft Installation
  85
- Cylinder/Piston
  87
  - Cylinder Removal
    89
  - Piston Removal
    89
  - Piston Installation
    93
  - Cylinder Installation
    93
- Drive and Driven Pulleys/Kick Starter
  96
  - Clutch Outer Nut 1
    96
  - Left Crankcase Cover
    97
  - Kick Starter
    98

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