KYMCO SUPER8 50 2T Service Manual
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KYMCO SUPER8 50 2T Service Manual

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1
SPECIFICATIONS................................................................................ 1
General Information.................................................................. 2
Inspection/Adjustment .............................................................. 3
Lubrication System ..................................................................... 4
Engine Removal/Installation.................................................. 5
Cylinder Head/Cylinder/Piston............................................... 6
A.c. Generator............................................................................... 7
Final Reduction............................................................................. 9
Crankcase/Crankshaft ............................................................. 10
Carburetor .................................................................................... 11
Frame Covers................................................................................. 12
Steering Handlebar/FRONT WHEEL/FRONT BRAKE/
FRONT SHOCK ABSORBER/FRONT FORK ..................................... 13
Electrical Equipment................................................................. 15
Instrument/Switches/Lights .................................................... 16
Exhaust Emission Control System........................................17

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  • Page 1 1.SPECIFICATIONS SUPER8 50 2T TABLE OF CONTENTS SPECIFICATIONS................1 GENERAL INFORMATION..............2 INSPECTION/ADJUSTMENT .............. 3 LUBRICATION SYSTEM ..............4 ENGINE REMOVAL/INSTALLATION..........5 CYLINDER HEAD/CYLINDER/PISTON..........6 A.C. GENERATOR................7 KICK STARTER/DRIVE PULLEY/CLUTCH/DRIVEN PULLEY... 8 FINAL REDUCTION................9 CRANKCASE/CRANKSHAFT ............. 10 CARBURETOR ..................11 FRAME COVERS.................

  • Page 2: Specifications

    1.SPECIFICATIONS SUPER8 50 2T SPECIFICATIONS Name & Model SUPER8 50 2T Lubrication oil capacity (liter) Overall length (mm) 2040 Air cleaner type & No. Wet, single Overall width (mm) Fuel capacity (liter) Overall height (mm) 1240 Type Plunger type Wheel base (mm) 1350 ⎯...

  • Page 3: Table Of Contents

    SUPER8 50 2T . GENERAL INFORMATION ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ GENERAL INFORMATION ________________________________________________________________________________ ENGINE SERIAL NUMBER/IDENTIFICATION ............ 2- 1 SERVICE PRECAUTIONS ................... 2- 2 SERVICE INFORMATION ..................2- 10 TORQUE VALUES ....................2- 12 SPECIAL TOOLS ....................2- 13 LUBRICATION POINTS ..................

  • Page 4: Engine Serial Number/Identification

    . GENERAL INFORMATION SUPER8 50 2T ENGINE SERIAL NUMBER/IDENTIFICATION Location of Engine Serial Number...

  • Page 5: Service Precautions

    SUPER8 50 2T . GENERAL INFORMATION 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.
  • Page 6 . GENERAL INFORMATION SUPER8 50 2T 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.
  • Page 7 SUPER8 50 2T . GENERAL INFORMATION If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. Confirm Capacity After operation, terminal caps shall be installed securely. When taking out the connector, the lock on the connector shall be released before operation.
  • Page 8 . GENERAL INFORMATION SUPER8 50 2T connector shall inserted completely. Snapping! 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 loose negative terminal.
  • Page 9 SUPER8 50 2T . GENERAL INFORMATION 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.
  • Page 10 . GENERAL INFORMATION SUPER8 50 2T Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner.
  • Page 11 SUPER8 50 2T . GENERAL INFORMATION 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 surrounding parts steering positions.
  • Page 12 . GENERAL INFORMATION SUPER8 50 2T Symbols: following symbols represent servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for lubrication.) Engine Oil : Apply grease for lubrication.

  • Page 13: Service Information

    SUPER8 50 2T . GENERAL INFORMATION SERVICE INFORMATION ENGINE Standard (mm) Service Limit (mm) SUPER8 50 2T SUPER8 50 2T Item ⎯ 0.10 Cylinder head warpage 38.970～38.955 38.90 Piston O.D.(5mm from bottom of piston skirt) 0.10 Cylinder-to- piston clearance 12.002～12.008 12.03...
  • Page 14 . GENERAL INFORMATION SUPER8 50 2T FRAME Standard (mm) Service Limit (mm) Item SUPER8 50 2T SUPER8 50 2T ⎯ Axle shaft runout Radial Front wheel rim runout Axial Front shock absorber spring free length 200.0 182.8 Rear wheel rim runout Brake drum I.D.

  • Page 15: Torque Values

    SUPER8 50 2T . GENERAL INFORMATION TORQUE VALUES ENGINE Item Thread dia. (mm) Torque (kg-m) Remarks 1.5～1.7 Cylinder head bolt BF7x115 (cold) Clutch drive plate nut 3.5～4.0 Clutch outer nut NH10 3.5～4.5 Drive face nut NH12 5.0～6.0 Oil check bolt 1.0～1.5...

  • Page 16: Special Tools

    . GENERAL INFORMATION SUPER8 50 2T SPECIAL TOOLS Tool Name Tool No. Remarks Universal bearing puller Crankshaft bearing removal Lock nut wrench, 39mm Drive pulley disassembly/assembly Lock nut socket wrench Top cone race holding Lock nut wrench, Stem lock nut tightening...
  • Page 17 SUPER8 50 2T . GENERAL INFORMATION Tool Name Tool No. Remarks Drive shaft bearing installation Final shaft Bearing outer driver, 37x40mm bearing installation Crankshaft bearing installation Outer driver, 24x26mm Driven pulley bearing installation Pilot, 10mm Front wheel bearing installation Bearing driver pilot, 17mm...

  • Page 18: Lubrication Points

    . GENERAL INFORMATION SUPER8 50 2T LUBRICATION POINTS ENGINE Lubrication Points Lubricant Remarks Crankcase sliding & movable JASO-FC or API-TC Cylinder movable parts Transmission gear (final gear) SAE-90# Kick starter spindle bushing Grease Drive pulley movable parts Grease Starter pinion movable parts...

  • Page 19: Wiring Diagram

    SUPER8 50 2T . GENERAL INFORMATION PEOPLE S 50 WIRING DIAGRAM 2-16...

  • Page 20: Cable & Harness Routing

    . GENERAL INFORMATION SUPER8 50 2T CABLE & HARNESS ROUTING Front Brake Reservoir Rear Stop Brake Front Stop Brake Rear Brake Cable Throttle Cable Speedometer Cable Front Brake Fluid Tube Regulator/Rectifier Horn 2-17...
  • Page 21 SUPER8 50 2T . GENERAL INFORMATION Dimmer Switch Turn Signal Switch Starter Switch Horn Switch Throttle Cable Ignition Switch Speedometer Cable Wire Harness Front Brake Fluid Tube Rear Brake Cable 2-18...
  • Page 22 . GENERAL INFORMATION SUPER8 50 2T Fuel Cap Fuel Unit Oil Meter Fuel Tube Oil Filter Reed Valve Muffler Air Injection Control Valve Seat Cable Fuel Tank Air Cleaner Oil Tank Motor Connect wire Ignition Coil Spark Plug Oil Tube...
  • Page 23 SUPER8 50 2T . GENERAL INFORMATION Battery (-) Cable Battery (+) Cable Oil Tube Spark Plug Cap Oil Control Cable Auto Bystarter wire A.C.G Connect wire Starter Relay Wire Harness Fuel Tank Cap 2-20...

  • Page 24: Troubleshooting

    . GENERAL INFORMATION SUPER8 50 2T TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw. Empty fuel tank Clogged float valve Fuel reaches Fuel does not...
  • Page 25 SUPER8 50 2T . GENERAL INFORMATION ENGINE STOPS IMMEDIATELY AFTER IT STARTS Symptom Inspection/Adjustment Probable Cause Check if fuel reaches carburetor by loosening drain screw. Empty fuel tank Clogged float valve Fuel does not Fuel reaches Clogged charcoal canister carburetor...
  • Page 26 . GENERAL INFORMATION SUPER8 50 2T Symptom Inspection/Adjustment Probable Cause Check carburetor gasket for air leaks. Carburetor not securely tightened No air leak Air leaks Faulty intake manifold gasket Deformed or broken carburetor O-ring Remove auto bystarter connecting wire and check if bypass fuel line is clogged.
  • Page 27 SUPER8 50 2T . GENERAL INFORMATION ENGINE LACKS POWER Symptom Inspection/Adjustment Probable Cause Start engine and accelerate lightly for observation. Clogged air cleaner Engine speed Clogged fuel filter Engine speed does not increase Clogged exhaust muffler increases sufficiently Faulty auto bystarter...
  • Page 28 . GENERAL INFORMATION SUPER8 50 2T POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Symptom Inspection/Adjustment Probable Cause Check ignition timing. Faulty CDI unit Incorrect timing Correct timing Faulty A.C. generator Check carburetor air screw adjustment. Mixture too rich (turn screw...
  • Page 29 SUPER8 50 2T . GENERAL INFORMATION POOR PERFORMANCE (AT HIGH SPEED) Symptom Inspection/Adjustment Probable Cause Check ignition timing. Faulty CDI unit Correct timing Incorrect timing Loose A.C.G. stator Faulty A.C. generator Check auto fuel valve for fuel supply. Empty fuel tank...
  • Page 30 . GENERAL INFORMATION SUPER8 50 2T CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause Worn or slipping drive belt Broken ramp plate Broken driven face spring Engine starts but Separated clutch lining motor-cycle does not Damaged driven pulley shaft splines...
  • Page 31 SUPER8 50 2T . GENERAL INFORMATION POOR SUSPENSION PERFORMANCE Symptom Probable Cause (Front and rear tire pressures are normal) Weak shock spring Suspension is too soft Excessive load Shock damper oil leaking Bent fork tube or shock rod Suspension is too...
  • Page 32 . GENERAL INFORMATION SUPER8 50 2T OIL METER 1. Motor oil indicator light does not come on when there is no motor oil (Ignition switch ON) Symptom Inspection/Adjustment Probable Cause Check battery circuit by operating turn Burned out fuse signals.
  • Page 33 SUPER8 50 2T . GENERAL INFORMATION FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Symptom Probable Cause Inspection/Adjustment Check battery circuit by operating turn signals. Burned out fuse Weak or dead battery Signals operate Signals dim, remain...
  • Page 34 . GENERAL INFORMATION SUPER8 50 2T STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustment Probable Cause Check operation of Burned out fuse stop switch by Weak or dead battery applying brake. Faulty stop switch Stoplight does Stoplight comes on...

  • Page 35: Table Of Contents

    . INSPECTION/ADJUSTMENT SUPER8 50 2T __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________ INSPECTION AND MAINTENANCE SCHEDULE .....3- 1 BRAKE SYSTEM ...............3- 4 MOVING DEVICE ..............3- 6 DAMPING DEVICE ..............3- 7 POWER DRIVE SYSTEM............3- 7 ELECTRICAL EQUIPMENT............3- 8 ENGINE ..................3- 9...

  • Page 36: Inspection And Maintenance Schedule

    . INSPECTION/ADJUSTMENT SUPER8 50 2T INSPECTION AND MAINTENANCE SCHEDULE (Note) 1. ○means time for inspection. 2. ☆means regular replacement for the specified parts. This inspection and maintenance schedule is based upon average riding conditions. Machines subjected to serve use, or ridden in unusually dusty areas, require more frequent servicing.
  • Page 37 . INSPECTION/ADJUSTMENT SUPER8 50 2T Frequency Inspection & Maintenance Item Judgment Standards Remarks Every 6 Every 12 Prior month months months ○ ○ ○ Tire crack and damage Groove Depth: Tire groove and ○ ○ ○ Front: 0.8mm abnormal wear Rear : 0.8mm...
  • Page 38 . INSPECTION/ADJUSTMENT SUPER8 50 2T Frequency Inspection & Maintenance Item Judgment Standards Remarks Every 6 Every 12 Prior month months months Performance and abnormal ○ ○ noise Conditions at low and high ○ ○ ○ Body speeds ○ ○ Exhaust smoke ○...

  • Page 39: Brake System

    . INSPECTION/ADJUSTMENT SUPER8 50 2T Master Cylinder BRAKE SYSTEM Inspect the brake fluid level. Recommend brake fluid: DOT4 Normal limit 10～20mm Rear BRAKE LEVER Measure the front and rear brake lever free plays. Free Play: Rear: 10～20mm △ <Rear> “...
  • Page 40 . INSPECTION/ADJUSTMENT SUPER8 50 2T <Rear> “ △ ” Marks BRAKE DRUM/SHOE 《Brake Shoe Wear》 Replace the brake shoes if the arrow on the brake arm aligns with reference mark“△” on the brake panel when the brake is fully applied.

  • Page 41: Moving Device

    . INSPECTION/ADJUSTMENT SUPER8 50 2T MOVING DEVICE TIRES 《Tire Pressure》 Check the tire pressure. ＊ Tire pressure should be checked when tires are cold. Tire Pressure (one rider) Front: 1.75 kg/cm² Rear: 2.25 kg/cm² Tire Size 120/70 − 14 50P Front 120/80 −...

  • Page 42: Damping Device

    . INSPECTION/ADJUSTMENT SUPER8 50 2T DAMPING DEVICE SHOCK ABSORBERS 《Oil Leak/Damage》 Fully apply the front brake and check the action of the front shock absorber by compressing it several times. Check the entire shock absorber assembly for looseness or damage.
  • Page 43 . INSPECTION/ADJUSTMENT SUPER8 50 2T ELECTRICAL EQUIPMENT IGNITION APPARATUS 0.6-0.7mm Gap, Wear and 《Spark Plug》 Fouling Deposits Remove the frame center cover. Remove the spark plug cap and spark plug. Check the spark plug for wear, fouling and carbon deposits.

  • Page 44: Engine

    . INSPECTION/ADJUSTMENT SUPER8 50 2T Throttle Stop Screw ENGINE BODY 《At High and Low Speeds》 ＊ The engine must be warm for accurate idle speed adjustment. Adjust the idle speed to the specified range by turning the throttle stop screw and air screw.

  • Page 45: Lubrication System

    . INSPECTION/ADJUSTMENT SUPER8 50 2T Wash the air cleaner element in detergent Squeeze out oil, squeeze out and allow to dry. excess oil dry ＊ Never use gasoline or organic vaporable oil with acid or alkali for washing. After washing, soak the element in clean engine oil SAE 10W-30# and squeeze out excess oil.

  • Page 46: Others

    . INSPECTION/ADJUSTMENT SUPER8 50 2T Filter Screen Clean the oil filter screen with compressed air. Install the oil filter in the reverse order of removal and fill the oil tank with specified oil up to the proper level. Bleed air from the oil pump and oil lines.
  • Page 47 . INSPECTION/ADJUSTMENT SUPER8 50 2T FUEL SYSTEM 《Throttle Grip Free Play》 Measure the throttle grip free play. Free Play: 2～6mm If the throttle grip free play does not fall within the specified range, adjust by loosening the lock nut and turning the adjusting nut.

  • Page 48: Table Of Contents

    . LUBRICATION SYSTEM SUPER8 50 2T ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ LUBRICATION SYSTEM ________________________________________________________________________________ SERVICE INFORMATION ..................4-2 TROUBLESHOOTING..................4-2 OIL PUMP REMOVAL ..................4-3 OIL PUMP INSPECTION..................4-3 OIL PUMP INSTALLATION .................. 4-4 OIL PUMP BLEEDING..................4-5 OIL TANK ......................4-6...
  • Page 49 . LUBRICATION SYSTEM SUPER8 50 2T LUBRICATION SYSTEM...
  • Page 50 . LUBRICATION SYSTEM SUPER8 50 2T SERVICE INFORMATION GENERAL INSTRUCTIONS • Use care when removing and installing the oil pump not to allow dust and dirt to enter the engine and oil line. • Do not attempt to disassemble the oil pump.

  • Page 51: Oil Pump Removal

    . LUBRICATION SYSTEM SUPER8 50 2T OIL PUMP REMOVAL Oil Pump Control Cable ＊ Do not allow foreign matters to enter the crankcase. Before removing the oil pump, clean the oil pump and crankcase surfaces. Remove the met-in box. ( 12-4)

  • Page 52: Oil Pump Installation

    . LUBRICATION SYSTEM SUPER8 50 2T OIL PUMP INSTALLATION ＊ • Lubricate the O-ring with grease or engine oil before installation. • Make sure that the oil pump is inserted into the crankcase. • Apply molybdenum disulfide or grease to the pump pinion.

  • Page 53: Oil Pump Bleeding

    . LUBRICATION SYSTEM SUPER8 50 2T Intake Manifold OIL PUMP BLEEDING ＊ • Air in the oil lines will block oil flow and result in severe engine damage. • Bleed air from the oil lines and oil pump whenever the oil lines or pump have been removed or there is air in the oil lines.

  • Page 54: Oil Tank

    . LUBRICATION SYSTEM SUPER8 50 2T Oil Meter OIL TANK OIL TANK REMOVAL Remove the met-in box. ( 12-5) Remove the frame body cover. ( 12-5) Remove the rear carrier. ( 12-5) Remove the oil meter connector. Remove the two bolts attaching the oil tank.

  • Page 55: Engine Removal/Installation

    . ENGINE REMOVAL/INSTALLATION SUPER8 50 2T ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION ________________________________________________________________________________ SERVICE INFORMATION ..................5-1 ENGINE REMOVAL....................5-2 ENGINE INSTALLATION..................5-4...
  • Page 56 SUPER8 50 2T . ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the motorcycle body, cables and wires during engine removal.
  • Page 57 . ENGINE REMOVAL/INSTALLATION SUPER8 50 2T ENGINE REMOVAL Air Cleaner Case Carburetor Cap Remove the frame body cover. ( 12-5) Remove the five bolts attaching the air cleaner case. Loosen the band between the air cleaner and carburetor to remove the air cleaner case.
  • Page 58 SUPER8 50 2T . ENGINE REMOVAL/INSTALLATION Rear Shock Absorber Lower Mount Bolt Remove the rear brake adjusting nut and disconnect the brake cable from the crankcase. Remove the rear brake cable clamp and rear brake cable. Remove the rear shock absorber lower mount bolt.
  • Page 59 . ENGINE REMOVAL/INSTALLATION SUPER8 50 2T Engine Hanger ENGINE HANGER BRACKET INSPECTION Inspect the stopper rubbers and bushings for damage and replace with new ones if necessary. Bushings Stopper Rubbers ENGINE INSTALLATION Install the engine in the reverse order of removal.

  • Page 60: Cylinder Head/Cylinder/Piston

    . CYLINDER HEAD/CYLINDER/PISTON SUPER8 50 2T ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CYLINDER HEAD/CYLINDER/PISTON ________________________________________________________________________________ SERVICE INFORMATION ..................6-2 TROUBLESHOOTING..................6-2 CYLINDER HEAD....................6-3 CYLINDER/PISTON ..................... 6-6...
  • Page 61 SUPER8 50 2T . CYLINDER HEAD/CYLINDER/PISTON Torque: 1.1～1.7kg-m (cold) Torque: 1.5～1.7kg-m...
  • Page 62 . CYLINDER HEAD/CYLINDER/PISTON SUPER8 50 2T SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head, cylinder and piston can be serviced with the engine installed in the frame. • Before disassembly, clean the engine to prevent dust from entering the engine.
  • Page 63 SUPER8 50 2T . CYLINDER HEAD/CYLINDER/PISTON Spark Plug Cap CYLINDER HEAD REMOVAL Remove the rear carrier. Remove the frame body cover. ( 12-5) Remove the spark plug cap. Fan Cover/Engine Hood Remove the three bolts attaching the fan cover to remove the fan cover.
  • Page 64 . CYLINDER HEAD/CYLINDER/PISTON SUPER8 50 2T Combustion Chamber COMBUSTION CHAMBER DECABONIZING Remove the carbon deposits from the combustion chamber ＊ Avoid damaging the combustion cham- ber wall and cylinder mating surface. Mating Surface CYLINDER HEAD INSPECTION Check the cylinder head for warpage with a straight edge and feeler gauge.
  • Page 65 SUPER8 50 2T . CYLINDER HEAD/CYLINDER/PISTON Cylinder head Bolts Cylinder Head Bolts Installation Install and tighten the cylinder head bolts diagonally in 2 or 3 times. Torque: 1.5～1.7kg-m Install the spark plug. Torque: 1.1～1.7kg-m Spark Plug Cylinder Head Engine Hood Engine Hood Installation Install the engine hood.
  • Page 66 . CYLINDER HEAD/CYLINDER/PISTON SUPER8 50 2T CYLINDER/PISTON Cylinder CYLINDER REMOVAL Remove the met-in box and seat. Remove the frame body cover. Remove the cylinder head. Remove the two exhaust muffler joint lock nuts and two exhaust muffler lock bolts. Remove the exhaust muffler.
  • Page 67 SUPER8 50 2T . CYLINDER HEAD/CYLINDER/PISTON CYLINDER/PISTON INSPECTION Check the cylinder and piston for wear or damage. Clean carbon deposits from the exhaust port area. ＊ Be careful not to damage the cylinder inside wall. Measure the cylinder bore at three levels of A, B and C in both X and Y directions.
  • Page 68 . CYLINDER HEAD/CYLINDER/PISTON SUPER8 50 2T A Mark ＊ The cylinder has an ‘A’ mark or no mark on it. When replacing the cylinder with a new one, use a cylinder having the same mark as the old one. Measure the piston O.D. at a point 5mm from the bottom of the piston skirt.
  • Page 69 SUPER8 50 2T . CYLINDER HEAD/CYLINDER/PISTON PISTON RING INSPECTION Measure each piston ring end gap. Service Limits: Top/Second 0.40mm replace if over ＊ Set each piston ring squarely into the cylinder using the piston and measure the end gap. <Small End I.D. Measurement>...
  • Page 70 . CYLINDER HEAD/CYLINDER/PISTON SUPER8 50 2T Cylinder Gasket Install a new cylinder gasket on the mating surface between cylinder crankcase. Ring Pins Make sure that the ring end gaps are aligned with the piston ring pins in the ring grooves.

  • Page 71: A.c. Generator

    . A.C. GENERATOR SUPER8 50 2T ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ A.C. GENERATOR ________________________________________________________________________________ SERVICE INFORMATION ..................7-2 A.C. GENERATOR REMOVAL................7-3 A.C. GENERATOR INSTALLATION..............7-4...
  • Page 72 SUPER8 50 2T . A.C. GENERATOR Torque: 0.8～1.2kg-m Torque: 3.5～4.0kg-m Torque: 0.6～1.0kg-m Torque: 0.8～1.2kg-m...
  • Page 73 . A.C. GENERATOR SUPER8 50 2T SERVICE INFORMATION GENERAL INSTRUCTIONS • All A.C. generator maintenance and inspection can be made with the engine installed. • Refer to Section 15 for A.C. generator inspection. TORQUE VALUE Flywheel nut : 3.5～4.0kg-m SPECIAL TOOLS...
  • Page 74 SUPER8 50 2T . A.C. GENERATOR Fan Cover A.C. GENERATOR REMOVAL Remove the three bolts attaching the fan cover to remove the fan cover. Bolts Bolts Remove the cooling fan by removing the four bolts. Cooling Fan Hold the flywheel with an universal holder and then remove the 10mm flywheel nut.
  • Page 75 . A.C. GENERATOR SUPER8 50 2T Lock Nut Wrench Remove the A.C. generator flywheel using the flywheel puller. Flywheel Puller Remove the A.C. generator wire connector. A.C. Generator Wire Stator Pulser Coil Remove the two pulser coil bolts and pulser coil from the right crankcase.
  • Page 76 SUPER8 50 2T . A.C. GENERATOR A.C. Generator Wire Install the A.C. generator and pulser coil bolts. Connect the A.C. generator wire connector. Clean the taper hole in the flywheel off any burrs and dirt. Install the woodruff key in the crankshaft keyway.
  • Page 77 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY ________________________________________________________________________________ SERVICE INFORMATION ..................8- 2 TROUBLESHOOTING..................8- 2 KICK STARTER....................8- 3 DRIVE BELT......................8- 7 DRIVE PULLEY ....................8- 9 STARTER ONE-WAY CLUTCH DRIVE GEAR ............
  • Page 78 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY Torque: 5.0～6.0kg-m Torque: 3.5～4.5kg-m Torque: 3.5～4.0kg-m...
  • Page 79 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY SERVICE INFORMATION GENERAL INSTRUCTIONS • Avoid getting grease and oil on the drive belt and pulley faces. SPECIFICATIONS SUPER8 50 2T Standard (mm) Service Limit (mm) Item 20.01～20.025 24.24 Drive pulley collar O.D.
  • Page 80 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY Bolt KICK STARTER LEFT CRANKCASE COVER REMOVAL Remove the nine left crankcase cover bolts, left crankcase cover and dowel pins. Inspect the left crankcase cover seal rubber for damage or deterioration.
  • Page 81 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY Return Spring Remove the kick starter spindle and return spring from the left crankcase cover. Remove the kick starter spindle bushing. Kick Starter Spindle Return Spring Spindle KICK STARTER SPINDLE INSPECTION Inspect the kick starter spindle and gear for wear or damage.
  • Page 82 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY Inspect the kick starter spindle and driven Kick Starter Spindle Forcing Part gear forcing parts for wear or damage. Kick Starter Driven Gear Forcing Part KICK STARTER INSTALLATION Friction Spring Install the kick starter spindle bushing and return spring onto the left crankcase cover.
  • Page 83 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY First install the washer and then the circlip onto the kick starter spindle. Install the kick lever. Washer Circlip Dowel Pins LEFT CRANKCASE COVER INSTALLATION First install the dowel pins and then the seal rubber.
  • Page 84 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY DRIVE BELT Remove the left crankcase cover. INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: 16.5mm replace if below ＊...
  • Page 85 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY Clutch/Driven Pulley Remove the drive belt from the clutch/ driven pulley. Drive Belt Drive Belt DRIVE BELT INSTALLATION Turn the driven pulley clockwise and lift it up to expand the drive belt groove and then install a new drive belt.
  • Page 86 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY Drive Pulley Face Starting Ratchet DRIVE PULLEY REMOVAL Hold the drive pulley with the holder and remove the 12mm drive face nut. Remove the starting ratchet, 12mm washer and drive pulley face.
  • Page 87 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY Weight Roller MOVABLE DRIVE FACE INSPECTION Remove the weight rollers. Check each weight roller for wear or damage. Measure each roller O.D. Service Limit: 12.4mm replace if below Measure the movable drive face bushing assembly I.D.
  • Page 88 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY Install the drive belt on the crankshaft. Drive Pulley Face Install the drive face, starting ratchet and washer, then tighten the 12mm drive face nut. Torque: 3.5～4.0kg-m ＊ Keep grease or oil off the drive belt and drive pulley faces.
  • Page 89 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY CLUTCH/DRIVEN PULLEY 10mm Clutch Outer Nut Clutch Outer CLUTCH/DRIVEN PULLEY REMOVAL Remove the drive pulley. ( 8-8) Hold the clutch outer with the universal holder and remove the 10mm clutch outer nut.
  • Page 90 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY Remove the seal collar. Seal Collar Driven Pulley Oil Seal Pull out the guide roller pins from the driven pulley and then remove the O-rings and oil seal from the driven pulley.
  • Page 91 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below Measure the driven face spring free length. Service Limit: 82.6mm replace if below Check the driven face assembly for wear or damage.
  • Page 92 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY Inner Bearing DRIVEN PULLEY FACE BEARING REPLACEMENT Check the needle bearings in the driven face and replace them if they have excessive play, damage or abnormal noise. Drive the inner bearing out of the driven pulley face.
  • Page 93 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY Bearing Driver Pilot Drive in a new needle bearing into the driven face with the mark facing up. Outer Driver, 24x26mm Oil Seal Driven Pulley CLUTCH/DRIVEN PULLEY ASSEMBLY First install the movable driven face onto the driven face.
  • Page 94 . KICK STARTER/DRIVE PULLEY/ SUPER8 50 2T CLUTCH/DRIVEN PULLEY Set the driven pulley, driven face spring and clutch assembly onto the clutch spring compressor. Compress the tool and install the 28mm drive plate nut. Tighten the 28mm nut to the specified torque.

  • Page 95: Final Reduction

    SUPER8 50 2T . FINAL REDUCTION ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ FINAL REDUCTION ________________________________________________________________________________ SERVICE INFORMATION ..................9-2 TROUBLESHOOTING..................9-2 FINAL REDUCTION DISASSEMBLY ..............9-3 FINAL REDUCTION INSPECTION ..............9-3 FINAL REDUCTION ASSEMBLY ................. 9-6...
  • Page 96 . FINAL REDUCTION SUPER8 50 2T...
  • Page 97 SUPER8 50 2T . FINAL REDUCTION SERVICE INFORMATION Specified Oil: SAE90# At disassembly: 0.12 liter At change: 0.1 liter SPECIAL TOOLS Bearing remover set, 12mm Bearing remover set, 15mm Crankcase assembly collar Crankcase assembly shaft Bearing outer driver, 37x40mm Bearing outer driver, 32x35mm...
  • Page 98 . FINAL REDUCTION SUPER8 50 2T Bolts FINAL REDUCTION DISAS-SEMBLY Remove the rear wheel. ( 14-3) Remove the left crankcase cover. ( 8-4) Remove the clutch/driven pulley. ( 8-15) Drain the transmission gear oil into a clean container. Remove the transmission case cover attaching bolts.
  • Page 99 SUPER8 50 2T . FINAL REDUCTION Inspect the final gear and final shaft for wear, damage or seizure. Countershaft Bearing Drive Shaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage.
  • Page 100 . FINAL REDUCTION SUPER8 50 2T Drive Shaft Bearing BEARING REPLACEMENT (Transmission Case Cover) Remove the transmission case cover bearings using the bearing remover. Remove the final shaft oil seal. Bearing Remover Set Bearing Outer Driver Handle Drive new bearings into the transmission case cover.
  • Page 101 SUPER8 50 2T . FINAL REDUCTION Drive new bearings into the left crankcase. Install a new drive shaft oil seal. Bearing Outer Driver FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase. Install the final gear and final shaft into the left crankcase.
  • Page 102 . FINAL REDUCTION SUPER8 50 2T Dowel Pins position Install the countershaft and gear into the left crankcase. Install resin washer onto countershaft. Install the dowel pins and a new gasket. Countershaft Resin Washer Install the transmission case cover. Transmission Case Cover...
  • Page 103 SUPER8 50 2T . FINAL REDUCTION Oil Check Bolt Hole/Filler After installation, fill the transmission case with the specified oil. ＊ • Place the motorcycle on its main stand on level ground. • Check the sealing washer for wear or damage.

  • Page 104: Crankcase/Crankshaft

    SUPER8 50 2T . CRANKCASE/CRANKSHAFT _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ CRANKCASE/CRANKSHAFT _________________________________________________________________________________________ SERVICE INFORMATION ..................10-2 TROUBLESHOOTING..................10-2 CRANKCASE SEPARATION ................10-3 CRANKSHAFT REMOVAL ................... 10-3 CRANKSHAFT INSPECTION................10-4 CRANKSHAFT INSTALLATION ................10-5 CRANKCASE ASSEMBLY ................... 10-7 10-0...
  • Page 105 SUPER8 50 2T . CRANKCASE/CRANKSHAFT Torque: 0.8～1.2kg-m 10-1...

  • Page 106: Carburetor

    SUPER8 50 2T . CRANKCASE/CRANKSHAFT SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. • The following parts must be removed before separating the crankcase. Engine ( Section 5) Driven pulley ( Section 9) Carburetor ( Section 11) A.C.
  • Page 107 SUPER8 50 2T . CRANKCASE/CRANKSHAFT CRANKCASE SEPARATION Remove the crankcase attaching bolts. Bolts Attach the crankcase puller on the right crankcase and remove the right crankcase from the left crankcase. Crankcase Puller Crankcase Puller CRANKSHAFT REMOVAL Attach the crankcase puller on the left crankcase and remove the crankshaft from the left crankcase.
  • Page 108 SUPER8 50 2T . CRANKCASE/CRANKSHAFT Remove the remaining bearing on the crankshaft side using the universal bearing puller. ＊ When separating the crankcase, the oil seals must be removed. Replace the oil seals with new ones. Universal Bearing Puller CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance.
  • Page 109 SUPER8 50 2T . CRANKCASE/CRANKSHAFT Measure the crankshaft runout. Service Limit 0.150mm 0.100mm replace if over replace if over Check the crankshaft bearings for excessive play. The bearings must be replaced if they are noisy or have excessive play. Play...
  • Page 110 Bearing Outer Driver, 42x47mm Pilot, 20mm Crankcase Assembly Tool Install the crankshaft into the left crankcase. ＊ • Apply KYMCO ULTRA motor oil or molybdenum disulfide crankshaft bearings and connecting rod big end. • Apply grease to the lip of the oil seal and then install it.
  • Page 111 SUPER8 50 2T . CRANKCASE/CRANKSHAFT Dowel Pins CRANKCASE ASSEMBLY Install the dowel pins and a new gasket to the crankcase mating surface. Crankcase Assembly Tool Assemble the crankcase halves. Crankcase Assembly Collar Oil Seal The distance between the right crankcase oil seal and crankcase surface is about 12.5±0.5...
  • Page 112 SUPER8 50 2T . CRANKCASE/CRANKSHAFT The distance between the left crankcase oil seal and crankcase surface is about 1.0mm. Oil Seal 1.0mm Install and tighten the crankcase attaching bolts. ＊ After assembly, check the crankshaft for smooth operation. 10-8...
  • Page 113 SUPER8 50 2T . CARBURETOR _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ CARBURETOR _________________________________________________________________________________________ SERVICE INFORMATION ..................11- 2 TROUBLESHOOTING..................11- 2 THROTTLE VALVE DISASSEMBLY ..............11- 3 THROTTLE VALVE INSTALLATION..............11- 4 CARBURETOR REMOVAL .................. 11- 5 AUTO BYSTARTER ..................... 11- 6 FLOAT CHAMBER ....................
  • Page 114 SUPER8 50 2T CARBURETOR 11-1...
  • Page 115 SUPER8 50 2T . CARBURETOR SERVICE INFORMATION GENERAL INSTRUCTIONS • When working with gasoline, keep away from sparks and flames.. • Note the locations of O-rings when disassembling and replace them with new ones during assembly. • All cables, fuel lines and wires must be routed and secured at correct locations.
  • Page 116 SUPER8 50 2T CARBURETOR THROTTLE VALVE DIS-ASSEMBLY Remove the rear carrier. ( 12-5) Remove the met-in box. ( 12-4) Remove the rubber cover. Loosen carburetor cap and the throttle valve. Rubber Cover Disconnect the throttle cable from the Throttle Valve throttle valve.
  • Page 117 SUPER8 50 2T . CARBURETOR Remove the jet needle by removing the needle clip. Needle Clip Check the jet needle and throttle valve for wear or damage. Jet Needle Throttle Valve Rubber Seal Carburetor Cap THROTTLE VALVE INSTALLATION Install the jet needle on the throttle valve and secure with the needle clip.
  • Page 118 SUPER8 50 2T CARBURETOR Groove Install the throttle valve by aligning the groove in the throttle valve with the throttle stop screw. Throttle Stop Screw Carburetor Cap Tighten the carburetor cap. After installation, perform the following adjustments and inspections. • Throttle cable free play ( 3-12) •...
  • Page 119 SUPER8 50 2T . CARBURETOR Remove the carburetor. AUTO BYSTARTER AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals. Resistance: 5Ω (10 minutes minimum after stopping the engine) If the resistance exceeds 5Ω, replace the auto bystarter with a new one.
  • Page 120 SUPER8 50 2T CARBURETOR Connect the auto bystarter yellow wire to the battery positive (+) terminal and green/ black wire to the battery negative (-) terminal and wait 5 minutes. Connect a hose to the fuel enriching circuit and blow the hose with mouth.
  • Page 121 SUPER8 50 2T . CARBURETOR AUTO BYSTARTER INSTALLATION Auto Bystarter Screws Install the auto bystarter into the carburetor body until it bottoms.. Install the set plate and then tighten the two screws. Set Plate FLOAT CHAMBER Screws Remove the two float chamber screws and the float chamber.
  • Page 122 SUPER8 50 2T CARBURETOR Float Valve FLOAT/FLOAT VALVE INSPECTION Inspect the float for damage or fuel inside the float. Check the float valve seat for wear or damage. Float Seat Main Jet JETS/SCREWS REMOVAL Before removing the throttle stop screw or air screw, record the number of rotations until it seats lightly.
  • Page 123 SUPER8 50 2T . CARBURETOR Needle Jet holder Main Jet FLOAT CHAMBER ASSEMBLY Install the main jet and needle jet holder. Install the air screw and throttle stop screw according to the rotations recorded. ＊ If the air screw must be replaced, be...
  • Page 124 SUPER8 50 2T CARBURETOR O-rings CARBURETOR INSTALLATION ＊ When installation, do not allow foreign particles to enter the carburetor. Check the carburetor insulator and O-ring for wear or damage. Install the carburetor and insulator onto the intake manifold and tighten the two lock nuts.
  • Page 125 SUPER8 50 2T . CARBURETOR Bolts REED VALVE REMOVAL Remove the rear carrier. Remove the frame body cover. Remove the four intake manifold bolts and gasket. Remove the reed valve and gasket. Intake Manifold Reeds Reed Stopper INSPECTION Check the reed valve for damaged or weak reeds.
  • Page 126 SUPER8 50 2T CARBURETOR Bolts Fuel Unit Fuel Tank FUEL TANK REMOVAL Remove the met-in box. ( 12-4) Remove the frame body cover. ( 12-5) Remove the rear carrier. ( 12-5) Disconnect the fuel tube and vacuum tube at the auto fuel tank.

  • Page 127: Frame Covers

    SUPER8 50 2T . FRAME COVERS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ FRAME COVERS ________________________________________________________________________________ SERVICE INFORMATION ..................12-2 FRAME COVERS REMOVAL/INSTALLATION ............ 12-3 EXHAUST MUFFLER REMOVAL ................ 12-8 12-0...
  • Page 128 SUPER8 50 2T . FRAME COVERS ASSEMBLY DRAWING 12-1...
  • Page 129 SUPER8 50 2T . FRAME COVERS SERVICE INFORMATION • When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged. Items Related for Removal • Handlebar front cover Headlight wire • Front cover •...
  • Page 130 . FRAME COVERS SUPER8 50 2T Bolts FRAME COVERS REMOVAL REAR CARRIER Remove the met-in box. First remove the two bolts and four nuts attaching the met-in box. Remove the met-in box Bolts Remove the three bolts attaching the rear carrier.
  • Page 131 SUPER8 50 2T . FRAME COVERS Remove the two screws on the bottom of the center cover. Remove the center cover. Remove the body cover. Screws FLOOR-FOOT REMOVAL Screws Remove the screws attaching the right and left side covers. Remove the right and left side covers by pulling them outward.
  • Page 132 . FRAME COVERS SUPER8 50 2T Bolts Remove the floor mat. Remove the center cover. ( 1 2-3) Remove the screws and bolts attaching the front right and left side covers. Remove the four bolts attaching the floor-foot. Remove the floor-foot.
  • Page 133 SUPER8 50 2T . FRAME COVERS Rear Step Remove the four bolts attaching the left and right rear step. Remove the rear step Bolts WINDSHIELD REMOVAL Remove the four bolts attaching the front windshield out cover. Remove the windshield out cover.
  • Page 134 . FRAME COVERS SUPER8 50 2T Nuts Remove the four nuts attaching the handlebar cover Remove the handlebar cover. The installation sequence is the reverse of removal. BOTTOM COVER REMOVAL Remove the four bolts attaching the bottom cover. Remove the bottom cover.
  • Page 135 SUPER8 50 2T . FRAME COVERS Lid Leg Shield. Clip Body. Nuts Remove the L/R side bolts attaching the front fender and front fender. Lock Bolts Lock Nut EXHAUST MUFFLER REMOVAL Remove two lock nuts from joint in the exhaust muffler.
  • Page 136 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION SERVICE INFORMATION ..................13-2 TROUBLESHOOTING.................... 13-3 FRONT WHEEL ...................... 13-4 HYDRAULIC BRAKE DRAWING................13-7 HYDRAULIC BRAKE ..................... 13-8 FRONT SHOCK ABSORBER ................13-13 STEERING HANDLEBAR ..................13-14 STEERING STEM ....................
  • Page 137 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK 4.5kg-m 6.0kg-m 13-1...
  • Page 138 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK SERVICE INFORMATION GENERAL INSTRUCTIONS • Remove the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down. • During servicing, keep oil or grease off the brake drum and brake linings.
  • Page 139 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK SPECIAL TOOLS Lock nut wrench Driver handle A Outer driver, 28x30mm Pilot, 10mm Ball race remover Outer driver, 37x40mm Pliers (close) Bearing remover Bearing remover head, 10mm TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling •...
  • Page 140 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK FRONT WHEEL REMOVAL Remove the motorcycle front wheel off the ground. Disconnect the speedometer cable. Speedometer Cable Axle Nut Remove the front axle nut and pull out the axle. Remove the front wheel.
  • Page 141 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK FRONT WHEEL BEARING Side Collar Remove the side collar and dust seal. Dust Seal Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly.
  • Page 142 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK Dust Seal Apply grease to a new dust seal lip and install the dust seal. Install the side collar. Pawls INSTALLATION Apply grease to the brake panel dust seal lip.
  • Page 143 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK HYDRAULIC BRAKE DRAWING 13-7...
  • Page 144 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK HYDRAULIC BRAKE (FRONT BRAKE) BRAKE FLUID REPLACEMENT/AIR BLEEDING Check the brake fluid level on level ground. ＊ • When operating the brake lever, the brake reservoir cap must be tightened securely to avoid splash of brake fluid.
  • Page 145 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK Fixed-Reed Install the brake pads in the reverse order of removal. Tighten the brake pad pin bolt. Torque: 1.5～2.0kg-m ＊ Keep grease or oil off the brake pads to avoid brake failure.
  • Page 146 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK Master Cylinder Main Diaphragm INSPECTION Measure the brake master cylinder I.D. Inspect the master cylinder for scratches or cracks. Service Limit: 12.75mm Snap Ring Spring Measure the brake master cylinder piston O.D.
  • Page 147 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK Bolts Place the brake master cylinder on the handlebar and install the holder with the “up” mark facing up. Also align the punch mark with the holder joint seam. First tighten the upper bolt and then tighten the lower bolt.
  • Page 148 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK Compressed Air Remove the pistons from the brake caliper. If necessary, use compressed air to squeeze out the pistons through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed pistons.
  • Page 149 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK ASSEMBLY Clean all removed parts. Apply silicon grease to the pistons and oil seals. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the brake caliper piston with grooved side facing out.
  • Page 150 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK INSPECTION Inspect the following items and replace if necessary. •Front shock absorber tube bending or damage. •Weak front shock absorber spring. •Damper and damper rod bending. •Oil seal damage or wear.
  • Page 151 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK Remove the throttle seat screw. Screw Screws Remove the throttle seat from the handlebar and disconnect the throttle cable from the throttle pipe. Remove the throttle pipe from the handlebar.
  • Page 152 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK Top Cone Race Remove the top cone race. ＊ • Be careful not to lose the steel balls (20 on top race and 15 on bottom race). • Clean the openings of frame covers with clean shop towels.
  • Page 153 STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK SUPER8 50 2T ABSORBER/FRONT FORK Top Steel Ball Apply grease to the top and bottom ball races and install 20 steel balls on the top ball race and 15 steel balls on the bottom ball race.

  • Page 154: Rear Wheel/Rear Brake/Rear Shock Absorber

    . REAR WHEEL/REAR BRAKE/REAR SUPER8 50 2T SHOCK ABSORBER ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER ________________________________________________________________________________ SERVICE INFORMATION ..................14-2 TROUBLESHOOTING..................14-2 REAR WHEEL ...................... 14-3 REAR BRAKE....................... 14-4 REAR SHOCK ABSORBER ................. 14-6 14-0...
  • Page 155 . REAR WHEEL/REAR BRAKE/REAR SUPER8 50 2T SHOCK ABSORBER 4.0kg-m 2.7kg-m 11.0kg-m 2.2kg-m 0.6kg-m 3.3kg-m 14-1...
  • Page 156 . REAR WHEEL/REAR BRAKE/REAR SUPER8 50 2T SHOCK ABSORBER SERVICE INFORMATION SPECIFICATIONS Standard (mm) Service Limit (mm) Item Rear wheel rim runout Rear brake drum I.D. Rear brake lining thickness 235.7 218.7 Rear shock absorber spring free length TORQUE VALUES Rear axle nut 11.0～13.0kg-m...

  • Page 157: Shock Absorber

    . REAR WHEEL/REAR BRAKE/REAR SUPER8 50 2T SHOCK ABSORBER Rear Axle Nut REAR WHEEL REMOVAL Remove the two exhaust muffler joint lock nuts. Remove the two exhaust muffler lock bolts. Remove the exhaust muffler. Remove the rear axle nut to remove the rear wheel.
  • Page 158 . REAR WHEEL/REAR BRAKE/REAR SUPER8 50 2T SHOCK ABSORBER REAR BRAKE Remove the rear wheel. ( 14-3) Inspect the rear brake drum. Measure the rear brake drum I.D. Service Limit: 95.5mm replace if over BRAKE LINING INSPECTION Measure the brake lining thickness.
  • Page 159 . REAR WHEEL/REAR BRAKE/REAR SUPER8 50 2T SHOCK ABSORBER Remove the brake cam bolt to remove the brake arm, wear indicator plate and felt seal. Remove the brake arm. Brake Cam Brake Arm REAR BRAKE ASSEMBLY Apply grease to the anchor pin and brake shoe moving parts.
  • Page 160 . REAR WHEEL/REAR BRAKE/REAR SUPER8 50 2T SHOCK ABSORBER Brake Cable Brake Arm Install the brake arm pin. Connect the brake cable and install the adjusting nut. Install the rear wheel. ( 14-3) Adjust the rear brake lever free play.

  • Page 161: Electrical Equipment

    SUPER8 50 2T . ELECTRICAL EQUIPMENT _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ ELECTRICAL EQUIPMENT _________________________________________________________________________________________ SERVICE INFORMATION ..................15- 1 TROUBLESHOOTING..................15- 1 CHARGING SYSTEM................... 15- 3 BATTERY ......................15- 4 IGNITION SYSTEM ....................15- 7 STARTING SYSTEM .................... 15- 11...
  • Page 162 . ELECTRICAL EQUIPMENT SUPER8 50 2T SERVICE INFORMATION GENERAL INSTRUCTIONS • It is not necessary to check the battery electrolyte or fill with distilled water. • Remove the battery from the motorcycle for charging. Do not remove the electrolyte cap..
  • Page 163 SUPER8 50 2T . ELECTRICAL EQUIPMENT IGNITION SYSTEM No spark at plug Engine starts but turns poorly • Faulty spark plug • Ignition primary circuit • Poorly connected, broken or shorted wire —Faulty ignition coil —Between A.C. generator and CDI unit —Poorly connected wire or connector...
  • Page 164 . ELECTRICAL EQUIPMENT SUPER8 50 2T CHARGING SYSTEM Dimmer Switch Ignition Switch Resistor A.C. Generator 15-3...
  • Page 165 SUPER8 50 2T . ELECTRICAL EQUIPMENT BATTERY BATTERY REMOVAL Remove the battery cover. Disconnect the battery cables . ＊ First disconnect the battery negative (-) cable and then the positive (+) cable. Remove the battery. The installation sequence is the reverse of removal.
  • Page 166 . ELECTRICAL EQUIPMENT SUPER8 50 2T PERFORMANCE TEST Warm up the engine. Remove the floor mat and front tool box cover. ＊ Use a fully charged battery to check the charging system output. Stop the engine and open the fuse box.
  • Page 167 SUPER8 50 2T . ELECTRICAL EQUIPMENT RESISTOR INSPECTION Remove the frame front cover. ( 12-3) Measure the resistance between the resistor with ground. Resistances: Resistor: 9.9～12.0Ω ＊ Faulty resistor is the cause of faulty operation of the auto bystarter. Resister REGULATOR/RECTIFIER INSPECTION Remove the front cover.
  • Page 168 . ELECTRICAL EQUIPMENT SUPER8 50 2T IGNITION SYSTEM Ignition Switch Ignition Coil Spark Plug A.C. Generator (Exciter Coil) B/L1 Fuse B/L1 Ignition G/B2 G/B1 Switch AUTO Light Battery REG/ CDI Unit control 15-7...
  • Page 169 SUPER8 50 2T . ELECTRICAL EQUIPMENT IGNITION COIL INSPECTION Continuity Test ＊ This test is to inspect the continuity of ignition coil. Remove the met-in box. ( 12-4) Measure the resistance between the ignition coil primary coil terminals. Resistance (20℃): 0.153～0.187Ω...
  • Page 170 . ELECTRICAL EQUIPMENT SUPER8 50 2T Performance Test Remove the ignition coil. Ignition Coil Inspect the ignition coil with an ignition coil tester. ＊ Follow the ignition coil tester manufac- turer‘s instructions. 1. Turn the changeover switch to 12V and connect the ignition coil to the tester.
  • Page 171 SUPER8 50 2T . ELECTRICAL EQUIPMENT CDI UNIT INSPECTION Remove the front cover. Disconnect the CDI coupler and remove the CDI unit. CDI Unit CDI CIRCUIT INSPECTION Measure the resistance between the Green Black/ Yellow Black/ Red terminals. Replace the CDI unit if the readings are not within the specifications in the table below.
  • Page 172 . ELECTRICAL EQUIPMENT SUPER8 50 2T STARTING SYSTEM Starter Button Starter Relay Ignition Switch Starter Motor 15-11...
  • Page 173 SUPER8 50 2T . ELECTRICAL EQUIPMENT Starter Relay STARTER RELAY INSPECTION Remove the foot-floor cover. Disconnect the starter relay coupler and then remove the starter relay. Connect the starter relay (D) terminal to the 12V battery positive (+) terminal and the relay (C) terminal to the battery negative (-) terminal.
  • Page 174 . ELECTRICAL EQUIPMENT SUPER8 50 2T STARTER MOTOR INSPECTION Connect a battery across the starter motor Starter Motor and check for its operation. Battery (+) Terminal ＊ 1. Do not turn the starter motor for a long time. 2. This inspection should be done with a fully charged battery.

  • Page 175: Instrument/Switches/Lights

    . INSTRUMENT/SWITCHES/LIGHTS SUPER8 50 2T _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ INSTRUMENT/SWITCHES/LIGHTS _________________________________________________________________________________________ SERVICE INFORMATION ..................16-1 TROUBLESHOOTING..................16-1 FUEL UNIT ......................16-2 OIL METER ......................16-3 SWITCHES......................16-4 STOP SWITCH INSPECTION/HORN ..............16-6 FRONT TURN SIGNAL LIGHT REPLACEMENT..........16-7 INSTRUMENT/HEADLIGHT................. 16-8...
  • Page 176 . INSTRUMENT/SWITCHES/LIGHTS SUPER8 50 2T SERVICE INFORMATION GENERAL INSTRUCTIONS • Wires should be connected to other wires of the same color. Couplers must be connected to other couplers of the same color. • All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting.
  • Page 177 . INSTRUMENT/SWITCHES/LIGHTS SUPER8 50 2T Fuel Unit FUEL UNIT ＊ No Smoking! REMOVAL Remove the seat. (2-4) Remove the body cover. (2-5) Disconnect the fuel unit wire connectors. ＊ Do not damage the fuel unit wire. Remove the fuel unit.
  • Page 178 . INSTRUMENT/SWITCHES/LIGHTS SUPER8 50 2T Fuel Unit INSTALLATION The installation sequence is the reverse of removal. ＊ • Install the fuel unit at the connect position. Wire Connector OIL METER Oil Meter INSPECTION Remove the met-in box. ( 12-4) Remove the frame body cover. ( 12-4) Disconnect the oil meter wire connectors and remove the oil meter.
  • Page 179 . INSTRUMENT/SWITCHES/LIGHTS SUPER8 50 2T Move the oil meter float up and down to see if the oil indicator light will go out and come ＊ If the oil indicator light does not light, check for burned bulb, loose wire or connector.
  • Page 180 . INSTRUMENT/SWITCHES/LIGHTS SUPER8 50 2T Dimmer Switch DIMMER SWITCH INSPECTION Check for continuity between wire terminals. Color Symbol ○ ○ ○ ○ ○ ○ PASSING Passing Switch TURN SIGNAL SWITCH INSPECTION Check for continuity between the wire terminals. Color Symbol ○...
  • Page 181 . INSTRUMENT/SWITCHES/LIGHTS SUPER8 50 2T STARTER SWITCH INSPECTION Check for continuity between wire terminals. Push the starter button when measuring. Color Symbol FREE ○ ○ PUSH Starter Switch HORN SWITCH INSPECTION Check for continuity between wire terminals. Push the horn button when measuring.
  • Page 182 . INSTRUMENT/SWITCHES/LIGHTS SUPER8 50 2T Horn Terminal HORN INSPECTION Remove the frame front cover. ( 12-3) Disconnect the horn wire couplers. The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals. FRONT TURN SIGNAL LIGHT...
  • Page 183 . INSTRUMENT/SWITCHES/LIGHTS SUPER8 50 2T Bulb Socket INSTRUMENTS BULB REPLACEMENT Remove the handlebar rear cover. ( 2) Remove the bulb socket and replace the bulb. The installation sequence is the reverse of removal. INSTRUMENTS REPLACEMENT Remove the handlebar rear cover. ( 2) Disconnect the right and left handlebar switches wire couplers.

  • Page 184: Exhaust Emission Control System

    . EXHAUST EMISSION CONTROL SUPER8 50 2T SYSTEM ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ EXHAUST EMISSION CONTROL SYSTEM ________________________________________________________________________________ SCHEMATIC DRAWING ..................17-1 EXHAUST EMISSION CONTROL SYSTEM ............17-1 TROUBLESHOOTING .................... 17-2 SERVICE INFORMATION..................17-2 SECONDARY AIR CLEANER ................. 17-3 AIR INJECTION CUT-OFF VALVE (A.I.C.V.)............17-3 REED VALVE ......................
  • Page 185 . EXHAUST EMISSION CONTROL SUPER8 50 2T SYSTEM SCHEMATIC DRAWING EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system adopted in this model utilizes the reed valve to draw secondary air into the exhaust system for re-combustion by means of exhaust pulsation so as to minimize the exhaust emission.
  • Page 186 . EXHAUST EMISSION CONTROL SUPER8 50 2T SYSTEM TROUBLESHOOTING High CO at idle speed 1. Damaged or clogged reed valve 2. Damaged or clogged air injection cut-off valve 3. Clogged air cleaner Backfiring at sudden deceleration 1. Damaged reed valve (malfunction) 2.
  • Page 187 . EXHAUST EMISSION CONTROL SUPER8 50 2T SYSTEM Secondary Air Cleaner / A.I.C.V. ECONDARY AIR CLEANER / AIR INJECTION CONTROL VALVE (A.I.C.V.) REMOVAL Remove the seat. ( 2-4) Remove the body cover. Disconnect the secondary air cleaner /(A.I.C.V) connecting tube.
  • Page 188 . EXHAUST EMISSION CONTROL SUPER8 50 2T SYSTEM Reed Valve Cover Bolt REED VALVE REMOVAL Disconnect the secondary air inlet tube connector. Remove the reed valve cover three bolts. Secondary Air Inlet Tube Clip Remove the three bolts attaching the reed valve cover and the reed valve.

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