KYMCO Super 8 50 Service Manual
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KYMCO Super 8 50 Service Manual

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See also: Owner's Manual
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO
50
Section 1 contains the precautions for all
operations stated in this manual. Read
them carefully before starting any
operation.
Section 2 is the removal/installation
procedures for the frame covers which
are subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
Adjustment procedures, safety rules and
Service Information for each part, starting
from periodic maintenance.
Sections 6 through 17 give instructions
for disassembly, assembly and inspection
of engine, chassis frame and electrical
equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.
Our company reserves the right to make
any alteration in the design.
information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
The

TABLE OF CONTENTS

FUEL SYSTEM
Front Wheel/FRONT BRAKE/
FRONT SUSPENSION
REAR WHEEL /REAR BRAKE /REAR
SUSPENSION
BATTERY/CHARGING SYSTEM/A.C.
GENERATOR
EXHAUST EMISSION CONTROL
SYSTEM
50
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

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Summary of Contents for KYMCO Super 8 50

  • Page 1 Super 8 PREFACE TABLE OF CONTENTS This Service Manual describes the technical features and servicing GENERAL INFORMATION procedures for the KYMCO FRAME COVERS/EXHAUST MUFFLER SUPER 8 INSPECTION/ADJUSTMENT LUBRICATION SYSTEM Section 1 contains the precautions for all operations stated in this manual. Read...

  • Page 2: Table Of Contents

    . GENERAL INFORMATION SUPER 8 50 ENGINE SERIAL NUMBER ....1- 1 LUBRICATION POINTS ......1-13 SPECIFICATIONS ........1- 2 CABLE & HARNESS ROUTING ..... 1-15 SERVICE PRECAUTIONS ...... 1- 3 WIRING DIAGRAM ........ 1-20 TORQUE VALUES ........1-11 TROUBLESHOOTUNG ......1-21 SPECIAL TOOLS ........

  • Page 3: Super

    . GENERAL INFORMATION SUPER 8 50 SPECIFICATIONS Air cleaner type & No Paper element Motorcycle Name & Type SUPER 8 50 Fuel capacity 6.0 liter Name & Model No. KP10BA(AAB6) 2040 Type ----- Overall length (mm) ------ Piston dia. (mm)

  • Page 4: Service Precautions

    . GENERAL INFORMATION SUPER 8 50 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 5 . GENERAL INFORMATION SUPER 8 50  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 6 . GENERAL INFORMATION SUPER 8 50  If the fuse is burned out, find the cause and repair it. Replace it with a new one Confirm according to the specified capacity. Capacity  After operation, terminal caps shall be installed securely.
  • Page 7 . GENERAL INFORMATION SUPER 8 50  The connector shall be inserted completely.  If the double connector has a lock, lock Snapping! it at the correct position.  Check if there is any loose wire.  Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
  • Page 8 . GENERAL INFORMATION SUPER 8 50  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 9 . GENERAL INFORMATION SUPER 8 50  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 10 . GENERAL INFORMATION SUPER 8 50  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 or surrounding parts in all steering positions.
  • Page 11 . GENERAL INFORMATION SUPER 8 50  Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for Engine Oil lubrication.) : Apply grease for lubrication.

  • Page 12: Torque Values

    . GENERAL INFORMATION SUPER 8 50 TORQUE VALUES STANDARD TORQUE VALUES Item Torque (kg-m) Item Torque (kg-m) 5mm bolt, nut 0.45-0.6 5mm screw 0.35-0.5 6mm bolt, nut 0.6-1.2 6mm screw, SH bolt 0.7-1.1 8mm bolt, nut 1.8-2.5 6mm flange bolt, nut 1.0-1.4...

  • Page 13: Special Tools

    . GENERAL INFORMATION SUPER 8 50 SPECIAL TOOLS Tool Name Tool No. Remarks Ref. Page 10-3 Bearing puller 10.12.15.18 mm E037 10.12.15.18mm bearing 10-4 12-6 Bushing remover L E032 11102 bush engine hanger rubber Bushing remover S EO19 11203 bush rear cushion under rubber...

  • Page 14: Lubrication Points

    . GENERAL INFORMATION SUPER 8 50 LUBRICATION POINTS ENGINE Lubrication Points Lubricant Genuine KYMCO Engine Oil (SAE15W-40) Valve guide/valve stem movable part APISG Engine Oil Cam lobes Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves...
  • Page 15 . GENERAL INFORMATION SUPER 8 50 FRAME The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle.

  • Page 16: Cable & Harness Routing

    . GENERAL INFORMATION SUPER 8 50 CABLE & HARNESS ROUTING Ignition Switch Low Beam realy Roll Sensor High Beam realy Horn Throttle Cable Fuel Pump Realy Front brake tube Speedometer 1-15...
  • Page 17 . GENERAL INFORMATION SUPER 8 50 Fuel Pump Fuel Level Indicator Fuel Tube Battery (-) Cable Battery (+) Cable Fuse 1-16...
  • Page 18 . GENERAL INFORMATION SUPER 8 50 Starter Relay Ignition Coil Fuel Injector O₂ Sensor Throttle Cable Fuel Tube Crankcase Breather Tube 1-17...

  • Page 19: Wiring Diagram

    . GENERAL INFORMATION SUPER 8 50 WIRING DIAGRAM 1-18...
  • Page 20 . GENERAL INFORMATION SUPER 8 50 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Possible cause  Faulty fuel pump 1. Check for operation of the fuel pump Abnormal Normal  Faulty pressure regulator 2. Inspect the fuel flow...
  • Page 21 . GENERAL INFORMATION SUPER 8 50 ENGINE LACKS POWER Possible cause  Brake dragging 1. Raise wheel off the ground Wheels do not  Worn or damaged wheel bearing and spin by hand spin freely Wheel spins freely  Faulty tire valve 2.
  • Page 22 . GENERAL INFORMATION SUPER 8 50 Possible cause  Oil level too high 9. Check oil level and condition Incorrect  Oil level too low  Contaminated oil Correct  Clogged oil 10. Remove cylinder head cover Valve train not ...
  • Page 23 . GENERAL INFORMATION SUPER 8 50 POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause  Improper ignition timing 1. Check ignition timing Incorrect Correct  Faulty pressure regulator 2. Inspect the fuel flow Abnormal Normal  Faulty injector 3. Inspect the fuel injector...
  • Page 24 . GENERAL INFORMATION SUPER 8 50 POOR PERFORMANCE AT HIGH SPEED Possible cause  Faulty ECU 1. Check ignition timing Incorrect Correct  Faulty pressure regulator 2. Inspect the fuel flow Abnormal Normal  Faulty injector 3. Inspect the fuel injector...
  • Page 25 . FRAME COVERS/EXHAUST MUFFLER NEW SUPER8 50 SCHEMATIC DRAWING...
  • Page 26 . FRAME COVERS/EXHAUST MUFFLER NEW SUPER8 50...
  • Page 27 . FRAME COVERS/EXHAUST MUFFLER NEW SUPER8 50...
  • Page 28 . FRAME COVERS/EXHAUST MUFFLER NEW SUPER8 50 SERVICE INFORMATION ...... 2-1 EXHAUST MUFFLER REMOVAL ..2-5 FRAME COVERS ........2-2 SERVICE INFORMATION GENERAL INSTRUCTIONS  When removing frame covers, use special care not to pull them by force because the cover joint claws may be damaged.

  • Page 29: Frame Covers

    . FRAME COVERS/EXHAUST MUFFLER NEW SUPER8 50 FRAME COVERS FRONT COVER REMOVAL Bolts Remove the screw on the front cover. Front Cover Screw Remove the two screws on the back of the front cover. Remove the front cover. Remove the two bolt and ten screws attaching the R/L mole side.
  • Page 30 . FRAME COVERS/EXHAUST MUFFLER NEW SUPER8 50 FRAME BODY COVER REMOVAL Center Cover Screws Remove the two screws on the battery cover. Remove the center cover Center Cover Remove the three bolts attaching the rear Bolts carrier. Remove the rear carrier. Rear Carrier Rear Step Remove the two bolt attaching the lefe and...
  • Page 31 . FRAME COVERS/EXHAUST MUFFLER NEW SUPER8 50 Remove the two screws on the center rear cover. Remove the center rear cover. Center Rear Cover. Remove the two bolts attaching the frame body cover. Bolts Bolts Remove the two bolts attaching the rear fender.
  • Page 32 . FRAME COVERS/EXHAUST MUFFLER NEW SUPER8 50 Discornnect the seat lock wire. Seat Lock Wire Discornnect the tail lamp wire connectors Remove the left and right body cover The installation sequence is the reverse of remove ＊ During removal, do not pull the joint claws forcedly to avoid damage.
  • Page 33 . FRAME COVERS/EXHAUST MUFFLER NEW SUPER8 50 Remove the decorative ring. Remove the leg shieid. Leg Shield The installation sequence is the reverse of remove Decorative Ring EXHAUST MUFFLER REMOVAL Disconnect the O₂ Sensor connector. Remove the two exhaust muffler joint lock nuts.

  • Page 34: Inspection/Adjustment

    . INSPECTION/ADJUSTMENT SUPER 8 50 SERVICE INFORMATION ....3-0 FINAL REDUCTION GEAR OIL ..3- 7 MAINTENANCE SCHEDULE ....3-2 DRIVE BELT ......... 3- 7 FUEL FILTER .......... 3-3 HEADLIGHT AIM ....... 3- 8 THROTTLE OPERATION ....3-3 NUTS/BOLTS/FASTENERS ..... 3- 9 AIR CLEANER ........
  • Page 35 . INSPECTION/ADJUSTMENT SUPER 8 50 Cylinder compression : 15kg/cm Ignition timing: 13°～ 28° CHASSIS Front brake free play : 10～20mm Rear brake free play : 10～20mm TIRE PRESSURE 1 Rider 2 Riders Front 1.5kg/cm 2.0kg/cm Rear 1.75kg/cm 2.25kg/cm TIRE SIZE:...

  • Page 36: Maintenance Schedule

    . INSPECTION/ADJUSTMENT SUPER 8 50 MAINTENANCE SCHEDULE Perform the periodic maintenance at each scheduled maintenance period. I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary. A: Adjust C: Clean R: Replace T : Tighten Regular Service Mileage (km) Whichever...
  • Page 37 . INSPECTION/ADJUSTMENT SUPER 8 50 2～6mm THROTTLE OPERATION Check the throttle grip for smooth movement. Measure the throttle grip free play. Free Play: 2～6mm Adjusting Nut Lock Nut Major adjustment of the throttle grip free play is made at the carburetor side.

  • Page 38: Air Cleaner

    . INSPECTION/ADJUSTMENT Super 8 Air Cleaner Case Cover AIR CLEANER AIR CLEANER REPLACEMENT Remove the air cleaner case cover by removing the 7 screws. ① Remove the air cleaner element by removing the four screws. Check the element and replace it if it is excessively dirty or damaged.
  • Page 39 . INSPECTION/ADJUSTMENT SUPER 8 50 VALVE CLEARANCE Cylinder Head Cover ＊ Inspect and adjust valve clearance while the engine is cold (below 35℃). Remove the frame cover. (  2-3) Remove the six bolts on the cylinder head cover. Remove the cylinder head cover. (  7-3) Remove the cylinder head cover..

  • Page 40: Ignition Timing

    . INSPECTION/ADJUSTMENT Super 8 Timing Hole Cap IGNITION TIMING ＊ The CDI unit is not adjustable. If the ignition timing is incorrect, check the ignition system. (  15-5) Remove the right of the fan cover. Timing Light Check the ignition timing with a timing light. When the engine is running at idle speed, the ignition timing is correct if the “F”...
  • Page 41 . INSPECTION/ADJUSTMENT SUPER 8 50 FINAL REDUCTION GEAR OIL OIL LEVEL CHECK ＊ Place the motorcycle on its main stand on level ground for oil level check. Stop the engine and remove the oil check bolt. The oil level shall be at the oil check bolt hole.

  • Page 42: Headlight Aim

    . INSPECTION/ADJUSTMENT Super 8 HEADLIGHT AIM Turn the ignition switch ON and start the Front Cover engine. Turn on the headlight switch. Adjust the headlight aim by turning the headlight aim adjusting screw. CLUTCH SHOE WEAR Adjusting Screw Start the engine and check the clutch operation by increasing the engine speed gradually.
  • Page 43 . INSPECTION/ADJUSTMENT SUPER 8 50 NUTS/BOLTS/FASTENERS Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found. (  1-11) WHEELS/TIRES Check the tires for cuts, imbedded nails or other damages.

  • Page 44: Lubrication System

    . LUBRICATION SYSTEM Super 8 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION ------------------------------------------------ 4- 1 TROUBLESHOOTING ----------------------------------------------------- 4- 1 ENGINE OIL/OIL FILTER ------------------------------------------------ 4- 2 OIL PUMP -------------------------------------------------------------------- 4- 2...
  • Page 45 . LUBRICATION SYSTEM Super 8 50 SERVICE INFORMATION GENERAL INSTRUCTIONS  The maintenance of lubrication system can be performed with the engine installed in the frame.  Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.

  • Page 46: Oil Pump

    . LUBRICATION SYSTEM Super 8 Lower Level ENGINE OIL/OIL FILTER OIL LEVEL ＊  Place the motorcycle upright on level ground for engine oil level check.  Run the engine for 2～3 minutes and check the oil level after the engine is stopped for 2～3 minutes.
  • Page 47 . LUBRICATION SYSTEM Super 8 50 Remove the gasket and dowel pins. Remove the starter idle gear and starter clutch. Gasket Remove the two bolts and oil separator Bolts cover. Oil Separator Cover Remove the oil pump driven gear nut to remove the oil pump driven gear and drive chain.
  • Page 48 . LUBRICATION SYSTEM Super 8 Screw DISASSEMBLY Remove the screw and disassemble the oil pump. Pump Body Outer Rotor INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.12mm Pump Body Outer Rotor Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.12mm Inner Rotor Measure the rotor end-to-pump body clearance.
  • Page 49 . LUBRICATION SYSTEM Super 8 50 Inner Rotor Outer Rotor ASSEMBLY Install the outer rotor, inner rotor and pump shaft into the pump body. ＊ Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor.
  • Page 50 . LUBRICATION SYSTEM Super 8 Bolts Install the oil separator cover and tighten the bolts. Oil Separator Cover Install the starter idle gear and starter clutch. Dowel Pin Starter Idle Gear Install the gasket and dowel pins. Gasket Starter Clutch Right Crankcase Cover Install the right crankcase cover and tighten the nine bolts.
  • Page 51 5. FUEL INJECTION SYSTEM Super 8 50 FUEL INJECTION SYSTEM SYSTEM DIAGRAM ................5 - 1 SYSTEM LOCATION ................5 - 2 SERVICE INFORMATION ..............5 - 3 TROUBLESHOOTING ................. 5 - 4 CHECK ENGINE LAMP (CELP) ............5 - 5 HOW TO SHOW THE FAILURE CODE ..........

  • Page 52: System Diagram

    5. FUEL INJECTION SYSTEM Super 8 50 SYSTEM DIAGRAM KEY ON FUEL PUMP ROLL T-MAP Voltage 曲軸感知器 曲軸感知器 進氣壓力及 感知器 含氧(O2) 大氣壓力感 感知器 知器 INDUCTIVE INJECTOR 進氣壓力及大氣壓力 感知器 IGNITION COIL 感知器 KEY OFF...
  • Page 53 5. FUEL INJECTION SYSTEM Super 8 50 Parts Location 01: Inductive ignition coil 02: Fuel pump 03: ECU 04: Fuel injector 05: WTS sensor 06: T-MAP sensor 07: ABV 08: TPS 09: Roll sensor(Angle detect sensor) 10: CPS 11: O2/O2 HT sensor...
  • Page 54 5. FUEL INJECTION SYSTEM Super 8 50 SERVICE INFORMATION GENERAL INSTRUCTIONS ＊ Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area.
  • Page 55 5. FUEL INJECTION SYSTEM Super 8 50 TROUBLESHOOTING Engine won’t start Backfiring or misfiring during acceleration  Battery voltage too low  Ignition system malfunction  Fuel level too low  Pinched or clogged fuel hose Poor performance (drive ability) and poor ...
  • Page 56 5. FUEL INJECTION SYSTEM Super 8 50 CHECK ENGINE LAMP (CELP)  When turning on the switch, the lamp will be lighted for 2 seconds then off. Let user to know the lamp is available and connect to ECU. ...
  • Page 57 5. FUEL INJECTION SYSTEM Super 8 50 How To Show Failure Code  You can read the failure code by as below :  Turn switch on. The CELP will be lighted for 2 seconds then off. The CELP start to blink to show the failure codes ...
  • Page 58 5. FUEL INJECTION SYSTEM Super 8 50 Failure Code Chart Blink Failure Fault Priority Fault management Codes description P0217 Engine 1.Slow down the vehicle and go to workshop for temperature checking immediately. overheat 2.Confirm if the engine temperature sensor or electric circuit is abnormality.
  • Page 59 5. FUEL INJECTION SYSTEM Super 8 50 Failure Code Blink Failure Fault description Priority Fault management Codes 1.Make sure if the connector of Throttle position sensor is P1122 Throttle position sensor connected correctly. movement speed 2.Check if theThrottle position sensor is adjusted.
  • Page 60 5. FUEL INJECTION SYSTEM Super 8 50 Failure Code Blink Failure Fault description Priority Fault management Codes 1. Check if the connector of ignition coil is loosen. P0350 Ignition coil or electric 2. Check if the ECU send signal to Ignition coil.
  • Page 61 5. FUEL INJECTION SYSTEM Super 8 50 Failure Code Blink Failure Fault description Priority Fault management Codes 1. Check if the lamp of CELP is broken. P0650 CELP electric circuit 2. Check if wires of CELP is broken. malfunction 1. Check if the connector of sensor is loosen.
  • Page 62 5. FUEL INJECTION SYSTEM Super 8 50 There are 36 pins attaching the ECU. Part number: 3920A-LHB6-900 Voltage inspection Connect the meter (+) probe to the F4(R/W)wire and the meter (-) probe to the H4(G/B) wire to measure the voltage.
  • Page 63 5. FUEL INJECTION SYSTEM Super 8 50 FUEL PUMP Connect the meter (+) probe to the red/black wire and the meter (-) probe to the green wire to measure the voltage from the ECU input to fuel pump unit. Standard : 8~16 V (Battery volt) To measure the resistance of the fuel pump to see if it is short circuit or not.
  • Page 64 5. FUEL INJECTION SYSTEM Super 8 50 T-MAP(Manifold Temperature Pressure) Sensor Connect the PDA or Fi diagnostic tool. Enter the Data Analyze Check if the manifold pressure data is malfunction. Turn the ignition switch to the “ON” position. If data is incorrect, and the T-map sensor is problem.
  • Page 65 5. FUEL INJECTION SYSTEM Super 8 50 ETS (Engine Temperature Sensor) Connect the meter (+) probe to the V/G wire and the meter (-) probe to the G/L wire to measure the voltage Standard : 5± 0.25 V Measure the resistance of the WTS Standard (20°...
  • Page 66 Measure the resistance of the O2 sensor heater. (2 white wire pin) Standard (20° C/68°F ): 6.7 ~9.5Ω Connect the PDA or KYMCO Fi diagnostic tool. Enter the Data Analyze Check Page 05 Turn the ignition switch to the “ON” position.
  • Page 67 5. FUEL INJECTION SYSTEM Super 8 50 ROLL SENSOR The engine should be stop when the vehicle incline over 65° for safety. When you place the vehicle back to normal position, you have to key-off and key-on the switch again, then it can be restarted.
  • Page 68 5. FUEL INJECTION SYSTEM Super 8 50 Connect the PDA or Fi diagnostic tool. Enter the Data Analyze Check ignition advance data malfunction. Turn the ignition switch to the “ON” position. Starting engine till the temperature up to 80° C.
  • Page 69 5. FUEL INJECTION SYSTEM Super 8 50 DIAGNOSTIC REPORT Reason of repair: □Maintenance □Breakdown Item Data Reference Memo ECU No Hardware Ver Software Ver QK0A00 Calibration Ver 04ALK1E4TB Model Name ALK1 Active Occurred History Air Temp.(° C) environ.temp ± 2 ° C Engine Temp.(Cooling)

  • Page 70: Operation Instructions

    5. FUEL INJECTION SYSTEM Super 8 50 Fi Diagnostic Tool Operation Instructions Part No. 3620A-LEB2-E00 1 Model No. 8 D ATA Analyze 2 Down Button 9 DTC Inspect 3 DTC indicator (Failure codes) 10 ECU Version 4 Enter or Exit...
  • Page 71 5. FUEL INJECTION SYSTEM Super 8 50 DTC INSPECTION Connect Fi diagnostic tool with the connector of harness wire located beside the Battery. Press the " Enter " button Check the software version Press the " Enter " button and then turn to the first page.
  • Page 72 5. FUEL INJECTION SYSTEM Super 8 50 Press the " Enter " button to check the DTC number Press the " Enter " button Press the " Enter " button Display the DTC number of the DTC-List. Refer to DTC summary list.
  • Page 73 5. FUEL INJECTION SYSTEM Super 8 50 Press the " UP " button Press the " Enter " button and then turn to thee previous page. Press the " UP " button Press the " Enter " button and then turn to the first page.
  • Page 74 5. FUEL INJECTION SYSTEM Super 8 50 DTC CLEAR PROCEDURE Choose " Load DTC " Press the " Down " button Press the " Enter " button The DTC indicator is lighting at that time. Clearing DTC until the DTC indicator is off.
  • Page 75 5. FUEL INJECTION SYSTEM Super 8 50 DATA ANALYSIS Choose " Data Analyze " Press the " Enter " button to enter page 01. The figure includes the engine speed, idle speed and the battery voltage. Refer to standard specification.
  • Page 76 5. FUEL INJECTION SYSTEM Super 8 50 The figure includes fuel injector interval, ignition advance angle and ABV angle. Refer to standard specification. Press the "Down" button to enter page 05. The figure includes O2 sensor voltage,O2 heater working condition and O2 correction.
  • Page 77 5. FUEL INJECTION SYSTEM Super 8 50 ADJUST Need to process the TPI/ABV reset after replacing a new ECU or clean Throttle Body. To make ECU set up and set up initially Choose " Adjust " Press the " Enter " button to TPI/ABV Reset Press the "...

  • Page 78: Engine Removal/Installation

    . ENGINE REMOVAL/INSTALLATION SUPER 8 50...
  • Page 79 6. ENGINE REMOVAL/INSTALLATION SUPER 8 50 SERVICE INFORMATION ...... 6-1 ENGINE INSTALLATION ....... 6-4 ENGINE REMOVAL ........ 6-2 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 80 . ENGINE REMOVAL/INSTALLATION SUPER 8 50 ENGINE REMOVAL Disconnect the battery negative cable. Remove the frame body cover. Disconnect the engine negative cable. Disconnect the spark plug high tension wire. Disconnect the auto bystarter wire connector. Auto Bystarter Wire Connector Disconnect the starter motor cable from the starter relay.
  • Page 81 6. ENGINE REMOVAL/INSTALLATION SUPER 8 50 Remove the rear shock absorber lower Rear Shock Absorber Lower Mount Bolt mount bolt. Engine Mounting Bolt Remove the four bolts of A.C. generator cooling fan cover and cooling fan cover. Remove the engine mounting bolt and pull out the engine with the engine hanger bracket backward.
  • Page 82 . ENGINE REMOVAL/INSTALLATION SUPER 8 50 ENGINE HANGER BRACKET INSTALLATION Engine Hanger Bracket Install the engine hanger bracket to the engine. Install the engine hanger bracket bolt and tighten the nut. ENGINE INSTALLATION Engine Mounting Bolt Install the engine and tighten the engine mounting bolt.

  • Page 83: Cylinder Head/Valves

    . CYLINDER HEAD/VALVES Super 8 50...
  • Page 84 7. CYLINDER HEAD/VALVES Super 8 50 SERVICE INFORMATION ...... 7-1 CYLINDER HEAD DISASSEMBLY ..7-7 TROUBLESHOOTING......7-2 CYLINDER HEAD ASSEMBLY ..... 7-8 CAMSHAFT REMOVAL ......7-3 CYLINDER HEAD INSTALLATION ..7-8 CYLINDER HEAD REMOVAL ....7-5 CAMSHAFT INSTALLATION ....7-9...
  • Page 85 . CYLINDER HEAD/VALVES Super 8 50 TORQUE VALUES Cylinder head nut 1.8~2.2kgf-m Apply engine oil to threads Valve clearance adjusting nut 0.7~1.1kgf-m Apply engine oil to threads SPECIAL TOOLS Valve spring compressor TROUBLESHOOTING  The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises.
  • Page 86 7. CYLINDER HEAD/VALVES Super 8 50 Cylinder Head Cover CAMSHAFT REMOVAL Remove the center cover. Remove the four cylinder head cover bolts to remove the cylinder head cover. Remove the two nuts attaching the secondary air inlet tube. O-ring Remove the cam chain tensioner cap screw and the O-ring.
  • Page 87 . CYLINDER HEAD/VALVES Super 8 50 Bolt Remove the two cylinder head bolts. Remove the four cylinder head nuts and washers. ＊ Diagonally loosen the cylinder head nuts in 2 or 3 times. Washer Camshaft Holder Remove the camshaft holder and dowel pins.
  • Page 88 7. CYLINDER HEAD/VALVES Super 8 50 Camshaft Bearings Check each camshaft bearing for play or damage. Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play. CAMSHAFT HOLDER DISASSEMBLY Take out the valve rocker arm shafts using a 5mm bolt.
  • Page 89 . CYLINDER HEAD/VALVES Super 8 50 Intake Manifold CYLINDER HEAD REMOVE Remove the camshaft. Remove the carburetor. Remove the exhaust muffler. Remove the carburetor intake manifold. Remove the cooling fan cover. Remove the engine cover bolts and screws. Separate the engine cover joint claws.
  • Page 90 7. CYLINDER HEAD/VALVES Super 8 50 CYLINDER HEAD DISASSEMBLY Valve Spring Compressor Remove the valve spring cotters, retainers, springs, spring seats and valve stem seals using a valve spring compressor. ＊  Be sure to compress the valve springs with a valve spring compressor.
  • Page 91 . CYLINDER HEAD/VALVES Super 8 50 VALVE /VALVE GUIDE Inspect each valve for bending, burning, scratches or abnormal stem wear. Check valve movement in the guide. Measure each valve stem O.D. Service Limits: IN : 4.90mm replace if below EX: 4.90mm replace if below Measure each valve guide I.D.

  • Page 92: Cylinder Head Installation

    7. CYLINDER HEAD/VALVES Super 8 50 Tap the valve stems gently with a plastic hammer for 2～3 times to firmly seat the cotters. ＊ Be careful not to damage the valves. Dowel Pins Gasket CYLINDER HEAD INSTALLATION Tighten the four stud bolts.

  • Page 93: Camshaft Installation

    . CYLINDER HEAD/VALVES Super 8 50 Cam Chain Camshaft Gear CAMSHAFT INSTALLATION Turn the flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Keep the round hole on the camshaft gear facing up and align the punch marks on the...
  • Page 94 7. CYLINDER HEAD/VALVES Super 8 50 Apply engine oil to a new O-ring and install Tighten the cam chain tensioner cap screw. ＊ Be sure to install the O-ring into the groove properly. O-ring Install a new cylinder head cover O-ring and install the cylinder head cover.

  • Page 95: Cylinder/Piston

    . CYLINDER/PISTON Super 8 50 Do not bend...
  • Page 96 . CYLINDER/PISTON Super 8 50 SERVICE INFORMATION ....... 8-1 PISTON REMOVAL ......... 8-2 TROUBLESHOOTING ......8-1 PISTON INSTALLATION ......8-6 CYLINDER REMOVAL ......8-2 CYLINDER INSTALLATION ....8-6 SERVICE INFORMATION GENERAL INSTRUCTIONS  The cylinder and piston can be serviced with the engine installed in the frame.
  • Page 97 . CYLINDER/PISTON Super 8 50 Cylinder CYLINDER REMOVAL Remove the cylinder head. Remove the cam chain guide. Remove the cylinder base bolts. Remove the cylinder. Remove the cylinder gasket and dowel pins. Gasket Dowel Pins Clean any gasket material from the cylinder surface.
  • Page 98 . CYLINDER/PISTON Super 8 50 Inspect the piston, piston pin and piston rings. Remove the piston rings. ＊ Take care not to damage or break the piston rings during removal. Clean carbon deposits from the piston ring grooves. Install the piston rings onto the piston and measure the piston ring-to-groove clearance.
  • Page 99 . CYLINDER/PISTON Super 8 50 Measure the piston pin O.D. Service Limit: 12.96mm replace if below Measure the piston O.D. ＊ Take measurement at 9mm from the bottom and 90 to the piston pin hole. Service Limit: 38.9mm replace if below Measure the piston-to-piston pin clearance.
  • Page 100 . CYLINDER/PISTON Super 8 50 Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if over Measure the connecting rod small end I.D. Service Limit: 13.06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston.

  • Page 101: Piston Installation

    . CYLINDER/PISTON Super 8 50 PISTON INSTALLATION Remove any gasket material from the crankcase surface. ＊ Be careful not to drop foreign matters into the crankcase. Install the piston, piston pin and a new piston pin clip. ＊  Position the piston “IN” mark on the intake valve side.
  • Page 102 . CYLINDER/PISTON Super 8 50 Loosely install the cylinder base bolts. Cam Chain Guide Install the cam chain guide. ＊ Insert the tab on the cam chain guide into the cylinder groove. Install the cylinder head. Tighten the cylinder base bolts.

  • Page 103: Drive And Driven Pulleys

    9. DRIVE AND DRIVEN PULLEYS Super 8 50...
  • Page 104 9. DRIVE AND DRIVEN PULLEYS Super 8 50 SERVICE INFORMATION ....... 9-1 DRIVE BELT ........... 9-5 TROUBLESHOOTING ......9-1 DRIVE PULLEY ........9-6 LEFT CRANKCASE COVER ....9-2 CLUTCH/DRIVEN PULLEY ....9-9 KICK STARTER ........9-2 SERVICE INFORMATION GENERAL INSTRUCTIONS ...
  • Page 105 9. DRIVE AND DRIVEN PULLEYS Super 8 50 Air Tube Band LEFT CRANKCASE COVER REMOVAL Loosen the drive belt air tube band screw. Remove the left crankcase cover bolts. Left Crankcase Cover Remove the seal rubber and dowel pins. Bolts...
  • Page 106 9. DRIVE AND DRIVEN PULLEYS Super 8 50 DRIVE PULLEY Tube Band Screw REMOVAL Starting Ratchet Drive Pulley Face Remove the left crankcase cover. Hold the drive pulley using an universal holder and remove the drive face nut and starting ratchet.
  • Page 107 9. DRIVE AND DRIVEN PULLEYS Super 8 50 Drive Pulley Collar DISASSEMBLY Remove the ramp plate. Movable Drive Face Assembly Ramp Plate Remove the weight rollers. INSPECTION Check each weight roller for wear or damage. Measure each weight roller O.D.
  • Page 108 9. DRIVE AND DRIVEN PULLEYS Super 8 50 Measure the movable drive face bushing I.D. Service Limit: 24.06mm replace if over Check the drive pulley collar for wear or damage. Measure the O.D. of the drive pulley collar sliding surface.
  • Page 109 9. DRIVE AND DRIVEN PULLEYS Super 8 50 Drive Pulley Collar Insert the drive pulley collar into the movable drive face. INSTALLATION Install the movable drive face onto the crankshaft. Movable Drive Face Assembly Drive Pulley Collar Driven Pulley Lay the drive belt on the driven pulley.
  • Page 110 9. DRIVE AND DRIVEN PULLEYS Super 8 50 Drive Pulley Face Install the drive pulley face, starting ratchet and drive face nut. ＊  When installing the drive pulley face, compress it to let the drive belt move downward to the lowest position so that the drive pulley can be tightened.
  • Page 111 9. DRIVE AND DRIVEN PULLEYS Super 8 50 Measure the clutch lining thickness. Service Limit: 1.5mm replace if below CLUTCH/DRIVEN PULLEY DISASSEMBLY Clutch/Driven Pulley Hold the clutch/driven pulley assembly with the clutch spring compressor. ＊ Be sure to use a clutch spring compressor to avoid spring damage.
  • Page 112 9. DRIVE AND DRIVEN PULLEYS Super 8 50 Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. Guide Roller Guide Roller Pin Remove the oil seal from the movable driven face.
  • Page 113 9. DRIVE AND DRIVEN PULLEYS Super 8 50 Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 34.06mm replace if over DRIVEN PULLEY FACE BEARING REPLACEMENT Drive the inner needle bearing out of the driven pulley face.
  • Page 114 9. DRIVE AND DRIVEN PULLEYS Super 8 50 Press a new needle bearing into the driven face. Circlip CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch. ＊ Keep grease off the clutch linings. Clutch Lining Retainer Plate...
  • Page 115 9. DRIVE AND DRIVEN PULLEYS Super 8 50 Install the movable driven face onto the driven face. Apply grease to the guide rollers and guide Guide Roller Guide Roller Pin roller pins and then install them into the holes of the driven face.
  • Page 116 9. DRIVE AND DRIVEN PULLEYS Super 8 50 Clutch/Driven Pulley Install the clutch outer. Clutch Outer Hold the clutch outer with the universal holder. Install and tighten the clutch outer nut. Torque: 5.5kg-m Special Flywheel Holder Install the drive belt.

  • Page 117: Final Reduction

    . FINAL REDUCTION Super 8 50 10-0...
  • Page 118 . FINAL REDUCTION Super 8 50 SERVICE INFORMATION ....... 10-1 FINAL REDUCTION INSPECTION ..10-2 TROUBLESHOOTING ......10-1 BEARING REPLACEMENT ....10-3 FINAL REDUCTION DISASSEMBLY ..10-2 FINAL REDUCTION ASSEMBLY ..10-4 SERVICE INFORMATION SPECIFICATIONS Specified Oil: GEAR OIL SAE 90# Oil Capacity: At disassembly : 0.21 liter...
  • Page 119 . FINAL REDUCTION Super 8 50 Bolt FINAL REDUCTION DISASSEMBLY Remove the rear brake cable. (  13-3) Remove the rear wheel. (  13-2) Remove the left crankcase cover. (  9-2) Remove the clutch/driven pulley. (  9-10) Drain the transmission gear oil into a clean container.

  • Page 120: Bearing Replacement

    . FINAL REDUCTION Super 8 50 Drive Shaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage. Countershaft Bearing Final Shaft Bearing Inspect the drive shaft and gear for wear or damage.
  • Page 121 . FINAL REDUCTION Super 8 50 Outer Driver, 32x35mm BEARING REPLACEMENT (LEFT CRANKCASE) Remove the drive shaft. Remove the drive shaft oil seal. Remove the left crankcase bearings using a bearing puller. Special Bearing Puller Bearing Puller, 12mm Drive new bearings into the left crankcase.
  • Page 122 . FINAL REDUCTION Super 8 50 Countershaft Install the countershaft and gear into the left crankcase. Install the dowel pins and a new gasket. Gasket Dowel Pins Install the transmission case cover. Transmission Case Cover Bolts Install and tighten the transmission case cover bolts.

  • Page 123: Crankcase/Crankshaft

    . CRANKCASE/CRANKSHAFT Super 8 50 11-0...
  • Page 124 . CRANKCASE/CRANKSHAFT Super 8 50 SERVICE INFORMATION ....... 11-1 CRANKSHAFT ........11-3 TROUBLESHOOTING......11-1 CRANKCASE ASSEMBLY ....11-4 CRANKCASE SEPARATION ....11-2 SERVICE INFORMATION GENERAL INSTRUCTIONS  This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation.
  • Page 125 . CRANKCASE/CRANKSHAFT Super 8 50 Crankcase Bolts CRANKCASE SEPARATION Remove the two crankcase attaching bolts. Separate the left and right crankcase halves. ＊ Do not damage the crankcase gasket surface. Gasket Remove the gasket and dowel pins. Dowel Pins Remove the crankshaft and cam chain from the left crankcase.
  • Page 126 . CRANKCASE/CRANKSHAFT Super 8 50 Remove the oil seal from the right crankcase. Check the oil seal lip for wear or deterioration. The installation sequence is the reverse of removal. CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance.
  • Page 127 . CRANKCASE/CRANKSHAFT Super 8 50 Turn the crankshaft bearings and check for excessive play. If they do not turn smoothly, quietly or if they fit loosely in the crankshaft, replace the crankshaft as a set. CRANKCASE ASSEMBLY Install the cam chain into the left crankcase.
  • Page 128 . CRANKCASE/CRANKSHAFT Super 8 50 Crankcase Bolts Tighten the two crankcase attaching bolts. Torque: 0.8~1.2kg-m 11-5...
  • Page 129 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 12-0...
  • Page 130 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 SERVICE INFORMATION ....12-1 FRONT SHOCK ABSORBER ....12-18 TROUBLESHOOTING ......12-2 FRONT FORK ......... 12-21 STEERING HANDLEBAR ..... 12-3 FRONT WHEEL ........12-4 SERVICE INFORMATION GENERAL INSTRUCTIONS  Remove the motorcycle frame covers before removing the front wheel. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down.
  • Page 131 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling  Excessively tightened steering stem top  Bent rim  Excessive wheel bearing play cone race  Broken steering balls  Bent spoke plate ...
  • Page 132 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers. (  2-2) Remove the two bolts attaching each of the front and rear brake levers. Remove the front and rear brake levers.
  • Page 133 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 Apply grease to the tip of the throttle pipe. Throttle Cable Install the throttle pipe and connect the throttle cable. Brake Levers Install the front and rear brake levers in the reverse order of removal.
  • Page 134 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 WHEEL RIM Check the wheel rim runout. Service Limits: Radial: 2.0mm replace if over Axial: 2.0mm replace if over Turn the wheel bearings and replace the bearings if they are noisy or have excessive Play play.
  • Page 135 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 ASSEMBLY Grease Grease Pack all bearing cavities with grease. Drive in the left bearing. Install the distance collar. Drive in the right bearing. ＊ Drive in the bearing squarely with the sealed end facing out.
  • Page 136 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 Upper Limit 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 spill of brake fluid.
  • Page 137 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 Reed Brake pads Brake Pad/Disk Replacement ＊ The brake pads must be replaced as a set to ensure the balance of the brake disk. Remove the two bolts attaching the brake caliper.
  • Page 138 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 BRAKE MASTER CYLINDER Brake Master Cylinder Bolts Removal First drain the brake fluid from the hydraulic brake system. ＊  When servicing the brake system, use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid.
  • Page 139 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 Inspection Measure the brake master cylinder I.D. Service Limit: 12.75mm Inspect the master cylinder for scratch or crack. Measure the brake master cylinder piston O.D. Service Limit: 12.6mm Before assembly, inspect the lst and 2nd rubber cups for wear.
  • Page 140 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 Disassembly Brake Caliper Seat Remove the brake caliper seat from the brake caliper. Remove the piston from the brake caliper. Compressed Air If necessary, use compressed air to squeeze out the piston through the brake fluid inlet...
  • Page 141 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 Place the brake master cylinder on the Punch Mark Bolts handlebar and install the holder with “up” mark facing up. Be sure to align the punch mark with the holder joint.
  • Page 142 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 Check the piston for scratch or wear. Measure the piston O.D. with a micrometer. Service Limit: 34mm Check the caliper cylinder for scratch or wear and measure the cylinder bore. Service Limit: 34.5mm Assembly Clean all removed parts.
  • Page 143 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 Installation Install the brake caliper and tighten the two bolts. Torque: 2.9～3.5kg-m Bolts Connect the brake fluid pipe to the brake caliper and tighten the fluid pipe bolt. Torque: 2.5～3.5kg-m Fill the brake reservoir with recommended brake fluid and bleed air from the brake syst em.
  • Page 144 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 Upper Mount Bolts FRONT SHOCK ABSORBER REMOVAL Remove the front wheel. (  12-4) Remove the front lower cover. (  2-2) Remove the front inner fender. Remove the front shock absorber upper mount bolts.
  • Page 145 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 Measure the front shock absorber spring free length. Service Limits: Right : 226.5mm Left : 226.5mm ASSEMBLY Top Nut Dust Seal Circlip Damper Oil Seal Damper Spring Shock Absorber Spring Front Shock...
  • Page 146 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 absorber tube. Install the shock absorber spring onto the front shock absorber tube and tighten the top nut. ＊ Install the front shock absorber spring with the closely wound coils facing down.

  • Page 147: Front Fork

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 FRONT FORK Long Socket Wrench REMOVAL Remove the steering handlebar. (  12-3) Remove the front wheel. (  12-4) Disconnect the speedometer cable. Remove the steering stem lock nut using long socket wrench.
  • Page 148 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Super 8 50 Drive new top and bottom ball races into the steering head using the outer driver. Driver Handle A ＊ Be sure to completely drive in the ball races. INSTALLATION Outer Driver, 37x40mm...
  • Page 149 . REAR WHEEL/REAR BRAKE/REAR Super 8 50 SHOCK ABSORBER ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER ________________________________________________________________________________ SERVICE INFORMATION .................. 13-2 TROUBLESHOOTING ..................13-2 REAR BRAKE ..................... 13-3 REAR WHEEL ------------------------------------------------------------------------------------ 13-7 REAR SHOCK ABSORBER ................13-8...
  • Page 150 . REAR WHEEL/REAR BRAKE/REAR Super 8 50 SHOCK ABSORBER...
  • Page 151 . REAR WHEEL/REAR BRAKE/REAR Super 8 50 SHOCK ABSORBER SERVICE INFORMATION GENERAL INSTRUCTIONS *When performing the service stated in this section,the engine and exhaust muffler must be cold to avoid scalding. *During servicing,keep oil or grease off the brake pads and brake disk.

  • Page 152: Shock Absorber

    . REAR WHEEL/REAR BRAKE/REAR Super 8 50 SHOCK ABSORBER REAR BRAKE REMOVAL BRAKE LINING INSPECTION Measure the brake lining thickness. Service Limit: 2.0mm replace if below ＊ Keep oil or grease off the brake linings. Brake Arm Brake Shoes REAR BRAKE DISASSEMBLY Remove the rear brake adjusting nut and disconnect the rear brake cable.
  • Page 153 . REAR WHEEL/REAR BRAKE/REAR Super 8 50 SHOCK ABSORBER Apply a small amount of engine oil to the felt seal and install it to the brake cam. Install the brake arm. ＊ Align the wide groove on the wear indicator plate with the wide tooth of the brake cam.
  • Page 154 . BATTERY/CHARGING SYSTEM/ Super 8 50 A.C. GENERATOR Regulator/Rectifier Battery Fuse A.C. Generator Fuse A.C. Generator Regulator/Rectifier Battery 14-0...
  • Page 155 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR Super 8 50 SERVICE INFORMATION ...... 14-1 A.C. GENERATOR CHARGING COIL ..14-6 TROUBLESHOOTING......14-2 RESISTOR INSPECTION ......14-6 BATTERY ..........14-3 A.C. GENERATOR REMOVAL ..... 14-6 CHARGING SYSTEM ......14-4 A.C. GENERATOR INATALLATION ..14-8 REGULATOR/RECTIFIER ......
  • Page 156 . BATTERY/CHARGING SYSTEM/ Super 8 50 A.C. GENERATOR SPECIFICATIONS Item Standard Capacity/Model 12V6AH Voltage Fully charged 13.1V Battery (20℃) Undercharged 12.3V Charging current STD: 0.4A Quick: 4.0A Charging time STD: 5～10hr Quick: 30min Capacity 0.144KW/5000rpm A.C. Generator Charging coil resistance (20℃) Yellow～Peach 0.1～1.0...
  • Page 157 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR Super 8 50 BATTERY Battery Cover REMOVAL Remove the battery cover screws on the floor board. Open the battery cover and remove the battery by removing the bolt and band. First disconnect the battery negative (-) cable and then the positive (+) cable.
  • Page 158 . BATTERY/CHARGING SYSTEM/ Super 8 50 A.C. GENERATOR CHARGING SYSTEM (-) Terminal Battery SHORT CIRCUIT TEST Disconnect the ground wire from the battery and connect an ammeter across the battery negative (-) terminal and the ground wire. Turn the ignition switch OFF and check for short circuit.
  • Page 159 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR Super 8 50 REGULATOR/RECTIFIER Regulator/Rectifier MAIN HARNESS CIRCUIT INSPECTION Remove the front covers. (  2-2) Remove the regulator/rectifier 4P coupler and check for continuity between the wire harness terminals according to the following :...
  • Page 160 . BATTERY/CHARGING SYSTEM/ Super 8 50 A.C. GENERATOR Charging Coil Wire A.C. GENERATOR CHARGING COIL ＊ The inspection of A.C. generator charging coil can be made with the engine installed. INSPECTION Disconnect the A.C. generator 2P connector. Measure the resistance between the A.C.
  • Page 161 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR Super 8 50 Remove the cooling fan by removing the four cooling fan attaching bolts. Hold the flywheel with an universal holder. Cooling Fan Remove the flywheel nut. Universal Holder Special Universal Holder Remove the A.C. generator flywheel using the flywheel puller.
  • Page 162 . BATTERY/CHARGING SYSTEM/ Super 8 50 A.C. GENERATOR Bolts Remove the A.C. generator wire set plate. Remove the pulser coil bolts. Remove the A.C. generator wire rubber sleeve and pulser coil from the right crankcase. Remove the two bolts and A.C. generator stator.
  • Page 163 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR Super 8 50 A.C. Generator Wire Connector Connect the A.C. generator wire connector. Woodruff Key Clean the taper hole in the flywheel off any burrs and dirt. Install the woodruff key in the crankshaft keyway.
  • Page 164 . BATTERY/CHARGING SYSTEM/ Super 8 50 A.C. GENERATOR Install the fan cover. Install the right side cover. (  2-4) Fan Cover 14-10...
  • Page 165 . IGNITION SYSTEM Super 8 50 Starter Relay A.C. Generator Spark Plug Ignition Coil Main Switch Roll sensor...
  • Page 166 . IGNITION SYSTEM Super 8 50 SERVICE INFORMATION GENERAL INSTRUCTIONS  Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present.  When servicing the ignition system, always follow the steps in the troubleshooting on page 17-2.
  • Page 167 . IGNITION SYSTEM Super 8 50 SPECIFICATIONS Item Standard Spark plug Standard type NGK CR7HSA Spark plug gap 0.6 ~ 0.7 mm 0.55~0.75Ω Inductive Ignition Coil Primary coil Throttle Position Sensor Input Volt 5V±0.1 Fuel Pump 1.0Ω~6.0Ω Fuel Injector 10.6Ω~15.9Ω...
  • Page 168 . IGNITION SYSTEM Super 8 50 IGNITION COIL REMOVAL Remove the met-in box. (  2-3) Remove the spark plug cap. Disconnect the ignition coil wires and remove the ignition coil bolt and ignition coil. Ignition Coil INSPECTION CONTINUITY TEST Measure the resistance between the ignition coil primary coil terminals.
  • Page 169 . IGNITION SYSTEM Super 8 50 PULSER COIL INSPECTION ＊ This test is performed with the stator installed in the engine. Remove the frame body cover. (  2-3) Disconnect the A.C. generator connector. Pulser Coil Coupler Measure the pulser coil resistance between the blue/yellow and green wire terminals.
  • Page 170 . IGNITION SYSTEM Super 8 50 A .C. GENERATOR INSPECTION CRANK POSITION SENSOR INSPECTION ＊ This test is performed with the stator installed in the engine. Remove the seat and met-in box. Disconnect the Crank Position Sensor Wire Coupler. Measure...
  • Page 171 . IGNITION SYSTEM Super 8 50 REMOVAL/INSTALLATION Disconnect the connector and remove two screws, then remove tilt switch. Installation is in the reverse order of removal. ＊ Install the tilt switch with its “up” mark facing up. Tighten the mounting screws securely.

  • Page 172: Starting System

    . STARTING SYSTEM Super 8 50 Starter Motor Starter Relay 16-0...
  • Page 173 . STARTING SYSTEM Super 8 50 SERVICE INFORMATION ....... 16-1 STARTER MOTOR ........ 16-2 TROUBLESHOOTING ......16-1 STARTER RELAY ........16-4 SERVICE INFORMATION GENERAL INSTRUCTIONS  The removal of starter motor can be accomplished with the engine installed. SPECIFICATIONS Item...

  • Page 174: Starter Motor

    . STARTING SYSTEM Super 8 50 Bolts STARTER MOTOR REMOVAL ＊ Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn on the ignition switch and push the starter button to see if the starter motor operates properly.
  • Page 175 . STARTING SYSTEM Super 8 50 STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover. Also check for the continuity between the wire terminal and each brush.
  • Page 176 . STARTING SYSTEM Super 8 50 ASSEMBLY Commutator Apply grease to the dust seal in the front cover. Install the brushes onto the brush holders. Apply a thin coat of grease to the two ends of the armature shaft. Insert the commutator into the front cover.
  • Page 177 . STARTING SYSTEM Super 8 50 STARTER RELAY GROUND CIRCUIT Yellow/Red Wire INSPECTION Disconnect the starter relay wire connector. Check for continuity between the yellow/red wire terminal and ground. There should be continuity when the starter button is depressed. If there is no continuity, check the starter button for continuity and inspect the wire.
  • Page 178 . STARTING SYSTEM Super 8 50 Remove the starter clutch lock nut. Lock Nut Special Flywheel Holder ＊ Note that the lock nut is left threaded. Remove the starter clutch. Remove the starter idle gear and shaft. Flywheel Holder INSPECTION Inspect the operation of the starter drive gear when it is assembled on the clutch.
  • Page 179 . STARTING SYSTEM Super 8 50 Measure the clutch cover O.D. Service Limit: 27.94mm replace if over Measure the starter idle gear I.D. Clutch Cover Service Limit: 10.05mm replace if over Starter Idle Gear Measure the starter idle gear shaft O.D.

  • Page 180: Lights/Instruments/Switches

    . LIGHTS/INSTRUMENTS/SWITCHES Super 8 50 SERVICE INFORMATION ....17-0 IGNITION SWITCH ......17-3 TROUBLESHOOTING ......17-0 STOP SWITCHES/HORN ....17-4 FUEL UNIT ..........17-1 INSTRUMENTS ........17-4 HANDLEBAR SWITCHES ....17-2 HEADLIGHT/LIGHTS ......17-5 SERVICE INFORMATION GENERAL INSTRUCTIONS  An electric tester is needed to measure or test the electric equipment.
  • Page 181 . LIGHTS/INSTRUMENTS/SWITCHES Super 8 50 Fuel Unit FUEL UNIT ＊ No Smoking! REMOVAL Remove the met-in box. (  2-3) Remove the frame right side cover. (  2-4) Disconnect the fuel unit wire connector. Turn the fuel unit retainer counterclockwise to remove it.
  • Page 182 . LIGHTS/INSTRUMENTS/SWITCHES Super 8 50 HANDLEBAR SWITCHES INSPECTION Br/w Remove the handlebar front cover. (  2-2) Disconnect the handlebar switch couplers and check for continuity between wire terminals. If there is any abnormality found, check each switch. Blue/w HEADLIGHT SWITCH...
  • Page 183 . LIGHTS/INSTRUMENTS/SWITCHES Super 8 50 HORN SWITCH Color Light Green Black FREE ○ ○ PUSH SWITCH REPLACEMENT Remove the front covers. (  2-2) Remove the handlebar front cover. (  2-2) The installation sequence is the reverse of removal.
  • Page 184 . LIGHTS/INSTRUMENTS/SWITCHES Super 8 50 STOP SWITCH INSPECTION Remove the handlebar front cover. (  2-2) Disconnect the front stop switch wire coupler. Check for continuity between the wire terminals when the front brake lever is applied. The switch is normal if there is continuity.
  • Page 185 . LIGHTS/INSTRUMENTS/SWITCHES Super 8 50 Screw Front Cover HEADLIGHT REMOVAL Remove the screw on the front cover. Remove the two screws on the back of the front cover. Remove the front cover. The installation sequence is the reverse of removal.

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