KYMCO SUPER8 50 Service Manual
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KYMCO SUPER8 50 Service Manual

KYMCO SUPER8 50 Service Manual

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PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO SUPER8 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

SYSTEM
SUPER8 50
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18

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Summary of Contents for KYMCO SUPER8 50

  • Page 1: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION This Service Manual describes the FRAME COVERS/EXHAUST MUFFLER technical features and servicing procedures for the KYMCO SUPER8 50 INSPECTION/ADJUSTMENT LUBRICATION SYSTEM Section 1 contains the precautions for all FUEL SYSTEM operations stated in this manual. Read...

  • Page 2: General Information

    . GENERAL INFORMATION SUPER8 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 ........1-12...

  • Page 3: Specifications

    . GENERAL INFORMATION SUPER8 50 SPECIFICATIONS Motorcycle Name & Type SUPER8 50 Name & Model No. LEJ2 Air cleaner type & No Paper element, wet Overall length (mm) 1940 Fuel capacity 6.0 liter Overall width (mm) Type Overall height (mm) 1220 Piston dia.

  • Page 4: Service Precautions

    . GENERAL INFORMATION SUPER8 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 SUPER8 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. Disconnect the battery negative (-) terminal before operation.
  • Page 6 . GENERAL INFORMATION SUPER8 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. When taking out the connector, the lock on the connector shall be released before operation.
  • Page 7 . GENERAL INFORMATION SUPER8 50 The connector shall be 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 or loose negative terminal.
  • Page 8 . GENERAL INFORMATION SUPER8 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 SUPER8 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 When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.
  • Page 10 . GENERAL INFORMATION SUPER8 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 SUPER8 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 SUPER8 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 SUPER8 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 SUPER8 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 SUPER8 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 SUPER8 50 CABLE & HARNESS ROUTING Brake Master Cylinder Rear Stop Switch Wire Front Stop Switch Wire Throttle Cable Rear Brake Cable Ignition Switch Speedometer Cable Front Brake Fluid Tube Regulator/Rectifier Horn Winker 1-15...
  • Page 17 . GENERAL INFORMATION SUPER8 50 Throttle Grip Regulator/Rectifier Control Lighting Ignition Switch Speedometer Cable Rear Brake Lever Horn Headlight Resistor Front Brake Fluid Tube 1-16...
  • Page 18 . GENERAL INFORMATION SUPER8 50 CDI Unit Fuse Battery (+) Cable Battery (-) Cable Starter Relay Fuel Tank Ignition Coil 1-17...
  • Page 19 . GENERAL INFORMATION SUPER8 50 Fuel Tube Fuel Filter Auto Cock Assy Fuel Throttle Cable Vacuum Tee Carburetor Overflow Tube Crankcase Breather Tube Ignition Coil Primary Wire Ignition Wire 1-18...
  • Page 20 . GENERAL INFORMATION SUPER8 50 Fuel Unit Crankcase Breather Tube Throttle Cable Wire Throttle Cable Vacuum Tube Crankcase Breather Tube Secondary Air Inlet Tube Ignition Coil Reed Valve Air Injection Cut-off Valve Vacuum Tube Fuel Tube Auto Bystarter 1-19...

  • Page 21: Wiring Diagram

    . GENERAL INFORMATION SUPER8 50 WIRING DIAGRAM 1-20...

  • Page 22: Troubleshooting

    . GENERAL INFORMATION SUPER8 50 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 fuel line between fuel tank and carburetor Clogged float oil passage...

  • Page 23: Engine Lacks Power

    . GENERAL INFORMATION SUPER8 50 ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and accelerate Clogged air cleaner lightly for observation Poor quality fuel (Restricted) Clogged fuel tank cap breather hole Clogged exhaust muffler Engine speed does not Engine speed...
  • Page 24 . GENERAL INFORMATION SUPER8 50 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Incorrect timing Correct timing Faulty pulser coil Check carburetor pilot screw adjustment Mixture too rich (turn screw...

  • Page 25: Poor Performance (At High Speed)

    . GENERAL INFORMATION SUPER8 50 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil Check valve clearance Improperly adjusted valve clearance Correctly adjusted Incorrectly adjusted Worn camshaft...
  • Page 26 . GENERAL INFORMATION SUPER8 50 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage between battery terminals Dead battery Voltage does not Normal voltage increase Faulty battery Measure resistance between AC generator coil terminals Faulty A.C.
  • Page 27 . GENERAL INFORMATION SUPER8 50 NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark Faulty old spark plug Check spark plug cap and high-tension wire...

  • Page 28: Frame Covers/Exhaust Muffler

    . FRAME COVERS/EXHAUST MUFFLER SUPER8 50 SCHEMATIC DRAWING...

  • Page 29: Service Information

    . FRAME COVERS/EXHAUST MUFFLER 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 30 . FRAME COVERS/EXHAUST MUFFLER SUPER8 50 Front Cover Bolts Screw FRAME COVERS FRONT COVER REMOVAL Remove the screw on the front cover. 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 31 . FRAME COVERS/EXHAUST MUFFLER 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.
  • Page 32 . FRAME COVERS/EXHAUST MUFFLER SUPER8 50 Remove the two screws on the center rear cover. Center Rear Cover. Remove the center rear cover. Remove the two bolts attaching the frame body cover. Bolts Bolts Remove the two bolts attaching the rear fender.

  • Page 33: Leg Shield Removal

    . FRAME COVERS/EXHAUST MUFFLER SUPER8 50 Seat Lock Wire Discornnect the 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 34: Exhaust Muffler Removal

    . FRAME COVERS/EXHAUST MUFFLER SUPER8 50 Leg Shield Remove the decorative ring. Remove the leg shieid. The installation sequence is the reverse of remove Decorative Ring EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts. Remove the two exhaust muffler lock bolts.

  • Page 35: Inspection/Adjustment

    . INSPECTION/ADJUSTMENT SUPER8 50 SERVICE INFORMATION....3-0 FINAL REDUCTION GEAR OIL..3- 7 MAINTENANCE SCHEDULE....3-2 DRIVE BELT.........3- 7 FUEL FILTER..........3-3 BRAKE SHOE ........3- 8 THROTTLE OPERATION.....3-3 BRAKE ADJUSTING NUT....3- 8 AIR CLEANER ........3-4 HEADLIGHT AIM .......3- 9 SPARK PLUG ..........3-4 CLUTCH SHOE WEAR.......3- 9 VALVE CLEARANCE......3-5...
  • Page 36 . INSPECTION/ADJUSTMENT SUPER8 50 Cylinder compression : 16 kg/cm Ignition timing: BTDC 28°/4000rpm CHASSIS Front brake free play: 10～20mm Rear brake free play : 10～20mm TIRE PRESSURE 1 Rider 2 Riders Front 1.5kg/cm 1.75kg/cm Rear 2.0kg/cm 2.25kg/cm TIRE SIZE: Front : 100 / 80 - 14...

  • Page 37: Maintenance Schedule

    . INSPECTION/ADJUSTMENT SUPER8 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 Frequency...

  • Page 38: Fuel Filter

    . INSPECTION/ADJUSTMENT SUPER8 50 Fuel Filter FUEL FILTER Remove the met-in box. ( 2-3) Check the fuel lines and replace any parts which show signs of deterioration, damage or leakage. ＊ Do not smoke or allow flames or sparks in your working area.

  • Page 39: Air Cleaner

    . INSPECTION/ADJUSTMENT SUPER8 50 Screws AIR CLEANER AIR CLEANER REPLACEMENT Remove the air cleaner case cover screws and the cover by removing the seven screws. Remove the air cleaner element by removing the four screws. Check the element and replace it if it is excessively dirty or damaged.

  • Page 40: Valve Clearance

    . INSPECTION/ADJUSTMENT SUPER8 50 Cylinder Head Cover VALVE CLEARANCE ＊ 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 41: Ignition Timing

    . INSPECTION/ADJUSTMENT SUPER8 50 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.

  • Page 42: Final Reduction Gear Oil

    . INSPECTION/ADJUSTMENT SUPER8 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 43: Brake Shoe

    . INSPECTION/ADJUSTMENT SUPER8 50 Punch Mark BRAKE SHOE Arrows Replace the brake shoes if the arrow on the wear indicator plate aligns with the punch mark on the brake panel when the brake is fully applied. Refer to page 12-7 and 13-3 for brake shoe replacement.

  • Page 44: Headlight Aim

    . INSPECTION/ADJUSTMENT SUPER8 50 If the free play do not fall within the limit, adjust by turning the adjusting nut. Adjusting Nut Front Cover HEADLIGHT AIM Turn the ignition switch ON and start the engine. Turn on the headlight switch.

  • Page 45: Nuts/Bolts/Fasteners

    . INSPECTION/ADJUSTMENT SUPER8 50 REAR Check the action of the rear shock absorber by compressing it several times. Check the entire shock absorber assembly for oil leaks, looseness or damage. Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn.

  • Page 46: Steering Handlebar

    . INSPECTION/ADJUSTMENT SUPER8 50 STEERING HANDLEBAR Check that the control cables do not interfere with handlebar rotation. Raise the front wheel off the ground and check that the steering handlebar rotates freely. If the handlebar moves unevenly, binds, or has vertical movement, adjust the steering head bearing.

  • Page 47: Lubrication System

    . LUBRICATION SYSTEM SUPER8 50 LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump...

  • Page 48: Service Information

    . LUBRICATION SYSTEM SUPER8 50 SERVICE INFORMATION.......4-1 ENGINE OIL/OIL FILTER ...... 4-2 TROUBLESHOOTING ......4-1 OIL PUMP..........4-3 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 49: Engine Oil/Oil Filter

    . LUBRICATION SYSTEM SUPER8 50 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 50: Oil Pump

    . LUBRICATION SYSTEM SUPER8 50 Bolt OIL PUMP REMOVAL Remove the exhaust muffler. Remove the rear fork. Remove the A.C. generator flywheel. ( 14-7) Remove the A.C. generator stator and pulsar coil. ( 14-6) Remove the eight right crankcase cover bolts and the right crankcase cover.
  • Page 51 . LUBRICATION SYSTEM SUPER8 50 Oil Pump Boby DISASSEMBLY Remove the three oil pump boby screws. Disassembly the oil pump. Screws INSPECTION Outer Rotor Measure the pump boby-to-outer rotor clearance. Service Limit: 0.12mm Oil Pump Boby Measure the inner rotor-to-outer rotor Outer Rotor clearance.

  • Page 52: Installation

    . LUBRICATION SYSTEM SUPER8 50 Outer Rotor Inner Rotor ASSEMBLY Install the outer rotor, inner rotor and pump shaft into the pump boby. ＊ Install the pump shaft by aligning the flat on the shaft with the flat in the inner rotor.
  • Page 53 . LUBRICATION SYSTEM SUPER8 50 Install the pump driven gear and secure it with the circlip. Pump Driven Gear Torque: 0.8～1.2kg-m Circlip Right Crankcase Cover Install the right crankcase cover and tighten the eight bolts. Torque: 0.8~1.2kgf-m ＊ Diagonally tighten the bolts in 2～3 times.

  • Page 54: Fuel System

    . FUEL SYSTEM SUPER8 50...
  • Page 55 . FUEL SYSTEM SUPER8 50...
  • Page 56 . FUEL SYSTEM SUPER8 50 SERVICE INFORMATION.......5-2 ACCELERATING PUMP .......5-10 TROUBLESHOOTING......5-3 CARBURETOR INSTALLATION..5-11 CARBURETOR REMOVAL.....5-4 PILOT SCREW ADJUSTMENT ....5-12 AUTO BYSTARTER .........5-4 FUEL TANK..........5-13 AIR CUT-OFF VALVE ......5-6 FUEL UNIT ..........5-14 VACUUM CHAMBER ......5-6 AIR CLEANER ........5-14 FLOAT CHAMBER........5-8 SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous.

  • Page 57: Troubleshooting

    . FUEL SYSTEM SUPER8 50 TROUBLESHOOTING Engine is hard to start Misfiring during acceleration • No spark at plug ( Section 15) • Faulty ignition system • Compression too low • Lean mixture • No fuel to carburetor • Faulty accelerating pump −Clogged fuel filter...

  • Page 58: Carburetor Removal

    . FUEL SYSTEM SUPER8 50 CARBURETOR REMOVAL Remove the frame right side cover. ( 2-4) Disconnect the auto bystarter wire connector. Remove the met-in box. ( 2-3) Auto Bystarter Wire Auto Bystarter Loosen the drain screw and drain the fuel from the float chamber.

  • Page 59: Auto Bystarter Inspection

    . FUEL SYSTEM SUPER8 50 Connect a hose to the fuel enriching circuit of Vacuum Pump the carburetor. Connect the auto bystarter yellow wire to the positive (+) terminal of a battery and green wire to the negative (-) terminal. Wait 5 minutes and blow the hose with mouth or vacuum pump.

  • Page 60: Air Cut-Off Valve

    . FUEL SYSTEM SUPER8 50 Screws Screws AIR CUT-OFF VALVE DISASSEMBLY Remove the two screws attaching the throttle cable set plate and the set plate. Remove the two screws attaching the air cut-off valve. Remove the spring and vacuum diaphragm.
  • Page 61 . FUEL SYSTEM SUPER8 50 Remove the needle holder and jet needle. ＊ Be careful not to damage the vacuum diaphragm. INSPECTION Jet Needle Inspect the needle for stepped wear. Inspect the vacuum piston for wear or damage. Inspect the diaphragm for deterioration and tears.

  • Page 62: Float Chamber

    . FUEL SYSTEM SUPER8 50 Screws FLOAT CHAMBER DISASSEMBLY Remove the three float chamber screws and the float chamber. Float Chamber Float Float Valve Loosen the float pin screw. Remove the float pin, float and float valve. Float Pin Needle Jet Holder...
  • Page 63 . FUEL SYSTEM SUPER8 50 Valve Seat INSPECTION Inspect the float valve and valve seat for damage or clogging. Inspect the float valve and valve seat contact area for stepped wear or contamination. ＊ Worn or contaminated float valve and...

  • Page 64: Accelerating Pump

    . FUEL SYSTEM SUPER8 50 Screws Diaphragm ACCELERATING PUMP DISASSEMBLY Remove the two accelerating pump cover screws and accelerating pump cover. Remove the spring and accelerating pump diaphragm. INSPECTION Inspect the accelerating pump diaphragm for cracks, damage or deterioration. Replace if necessary.

  • Page 65: Carburetor Installation

    . FUEL SYSTEM SUPER8 50 Connecting Tube Band CARBURETOR INSTALLATION Throttle Cable Tighten the drain screw. Install the carburetor onto the intake manifold, aligning the tab on the carburetor with the cutout in the intake manifold. Tighten the intake manifold band screw.

  • Page 66: Pilot Screw Adjustment

    . FUEL SYSTEM SUPER8 50 PILOT SCREW ADJUSTMENT * ADJUSTMENT ＊ • The pilot screw is factory pre-set and no adjustment is necessary. During carburetor disassembly, note the number of turns of the pilot screw and use as a reference when reinstalling it.
  • Page 67 . FUEL SYSTEM SUPER8 50 FUEL TANK REMOVE Remove the net-in box. ( 2-3) Remove the frame center cover. Remove the frame body cover. ( 2-3) Remove the four bolts on the fuel tank。 Disconnect the fuel unit wire connector.

  • Page 68: Fuel Unit

    . FUEL SYSTEM SUPER8 50 FUEL UNIT Fuel Unit Wire REMOVAL Remove the related parts. Disconnect the fuel unit wire connector. Turn the fixed plate on the fuel unit,take the fuel unit off. ＊ Do not bend the float arm on the fuel unit,otherwise the figure on the fuel meter will not correct.
  • Page 69 . FUEL SYSTEM SUPER8 50 The installation sequence is the reverse of removal. 5-15...

  • Page 70: Engine Removal/Installation

    . ENGINE REMOVAL/INSTALLATION SUPER8 50...

  • Page 71: Service Information

    6. ENGINE REMOVAL/INSTALLATION SUPER8 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 72: Engine Removal/Installation

    . ENGINE REMOVAL/INSTALLATION SUPER8 50 ENGINE REMOVAL Disconnect the battery negative cable. Remove the frame body cover. ( 2-3) Disconnect the spark plug high tension wire. Disconnect the auto bystarter wire connector. Disconnect the A.C. generator wire connector. A．C．G Wire Connector Disconnect the starter motor cable and earth cable from the starter motor.
  • Page 73 6. ENGINE REMOVAL/INSTALLATION SUPER8 50 Air Tube Band Loosen the drive belt air cleaner connecting tube band screw and remove the connecting tube. connecting tube Remove the rear brake adjusting nut, connector pin rear brake cable. Adjusting Nut Remove the L/R side the rear shock absorber Rear Shock Absorber Upper Mount Bolt upper mount bolts.
  • Page 74 . ENGINE REMOVAL/INSTALLATION SUPER8 50 ENGINE HANGER BRACKET REMOVAL Remove the return spring from the main stand. Remove the main stand. Main Stand Return Spring Bushing Remove the engine hanger bracket bolts and engine hanger bracket. Inspect the engine hanger bushings and stopper spring for wear or damage.
  • Page 75 6. ENGINE REMOVAL/INSTALLATION SUPER8 50 Install the removed parts in the reverse order Rear Shock Absorber Upper Mount Bolt of removal. ＊ Route the wires and cables properly. After installation, inspect and adjust the following: • Throttle grip free play ( 3-3) •...

  • Page 76: Cylinder Head/Valves

    . CYLINDER HEAD/VALVES SUPER8...

  • Page 77: Specifications

    7. CYLINDER HEAD/VALVES SUPER8 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 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame.

  • Page 78: Cylinder Head/Valves

    . CYLINDER HEAD/VALVES SUPER8 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 79: Camshaft Removal

    7. CYLINDER HEAD/VALVES SUPER8 50 Cylinder Head Cover CAMSHAFT REMOVAL Remove the center cover. ( 2-3) Remove the frame center. Remove the four cylinder head cover bolts to remove the cylinder head cover. Remove the cam chain tensioner sealing bolt...

  • Page 80: Camshaft Inspection

    . CYLINDER HEAD/VALVES SUPER8 Camshaft Holder Remove the camshaft holder and dowel pins. Camshaft Dowel Pins Remove the camshaft gear from the cam chain and remove the camshaft. Cam Chain Camshaft Gear CAMSHAFT INSPECTION Check each cam lobe for wear or damage. Measure the cam lobe height.

  • Page 81: Cylinder Head Removal

    7. CYLINDER HEAD/VALVES SUPER8 50 Rocker Arm Shaft CAMSHAFT HOLDER DISASSEMBLY Take out the valve rocker arm shafts using a 5mm bolt. Remove the valve rocker arms. 5mm Bolt Rocker Arm Camshaft Holder CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder, valve rocker arms and rocker arm shafts for wear or damage.
  • Page 82 . CYLINDER HEAD/VALVES SUPER8 Remove the cooling fan cover. ( 14-6) Remove the engine cover bolts and screws. Separate the engine cover joint claws. Cylinder Head Remove the cylinder head. Bolts Cylinder Head Gasket Dowel Pins Remove the dowel pins and cylinder head gasket.

  • Page 83: Cylinder Head Disassembly

    7. CYLINDER HEAD/VALVES SUPER8 50 Valve Spring Compressor CYLINDER HEAD DISASSEMBLY 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 84: Cylinder Head Assembly

    . CYLINDER HEAD/VALVES SUPER8 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 : 4.9mm replace if below EX: 4.9mm replace if below Valve Spring Compressor CYLINDER HEAD ASSEMBLY ＊...

  • Page 85: Camshaft Installation

    7. CYLINDER HEAD/VALVES SUPER8 50 Cylinder Head Install the cylinder head. Camshaft Holder CAMSHAFT HOLDER ASSEMBLY First assemble the camshaft holder. Install the intake and exhaust valve rocker arms and rocker arm shafts. ＊ • When installing the rocker arm shaft, align the shaft front end with the bolt hole of the camshaft holder.

  • Page 86: Cam Chain Tensioner Installation

    . CYLINDER HEAD/VALVES SUPER8 Washer Install the camshaft holder, washers and nuts on the cylinder head. Tighten the four cylinder head nuts and two bolts. Torque: Cylinder head nut: 1.8~2.2kgf-m ＊ • Apply engine oil to the threads of the cylinder head nuts.
  • Page 87 . CYLINDER/PISTON SUPER8 50 1.0kg-m Do not bend...

  • Page 88: Cylinder/Piston

    . CYLINDER/PISTON SUPER8 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. • After disassembly, clean the removed parts and dry them with compressed air before inspection.

  • Page 89: Cylinder Removal

    . CYLINDER/PISTON SUPER8 50 Cylinder CYLINDER REMOVAL Remove the cylinder head. ( 7-6) Remove the cam chain guide. Remove the cylinder. Dowel Pins Remove the cylinder gasket and dowel pins. Clean any gasket material from the cylinder surface. Gasket Piston Pin PISTON REMOVAL Remove the piston pin clip.
  • Page 90 . CYLINDER/PISTON SUPER8 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 91: Cylinder Inspection

    . CYLINDER/PISTON SUPER8 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 92: Piston Installation

    . CYLINDER/PISTON SUPER8 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 93: Piston Installation

    . CYLINDER/PISTON SUPER8 50 PISTON INSTALLATION Remove any gasket material from the crankcase surface. ＊ Be careful not to drop foreign matters into the crankcase. Piston Pin Clip Install the piston, piston pin and a new piston pin clip. ＊...
  • Page 94 . CYLINDER/PISTON SUPER8 50 Install the cam chain guide. ＊ Insert the tab on the cam chain guide into the cylinder groove. Install the cylinder head. ( 7-8) Loosely install the cylinder base bolts. Cam Chain Guide Tighten the cylinder base bolts.

  • Page 95: Drive And Driven Pulleys/Kick Starter

    9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 5.0～6.0kg-m 3.5-4.0g-m 3.5-4.5g-m...
  • Page 96 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 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 • The drive pulley, clutch and driven pulley can be serviced with the engine installed. •...

  • Page 97: Left Crankcase Cover

    9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 LEFT CRANKCASE COVER Left Crankcase Cover REMOVAL Loosen the drive belt air tube band screw. Remove the eight left crankcase cover bolts and left crankcase cover. Remove the seal rubber and dowel pins. Inspect the seal rubber for damage or deterioration.

  • Page 98: Installation

    9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Return Spring Spindle INSPECTION Inspect the kick starter spindle and gear for wear or damage. Inspect the return spring for weakness or damage. Inspect the kick starter spindle bushings for wear or damage. Plastic Bushing Spindle Bushing Inspect the starter driven gear for wear or...

  • Page 99: Left Crankcase Cover Installation

    9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Friction Spring Install the starter driven gear and friction spring onto the left crankcase cover as the figure shown. Starter Driven Gear First install the washer and then install the circlip. Install the kick lever. Washer Circlip Dowel Pins...

  • Page 100: Drive Belt

    9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 DRIVE BELT REMOVAL 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 Clutch Outer REPLACEMENT Remove the eight left crankcase cover bolts and left crankcase cover.
  • Page 101 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 INSTALLATION Turn the driven pulley clockwise to widen the drive belt groove and lay a new drive belt on the driven pulley. Drive Belt Drive Belt Drive Pulley Face Drive Face Nut Set the drive belt on the drive pulley face collar.
  • Page 102 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Ramp Plate Remove the ramp plate. Weight Roller Remove the weight rollers. INSPECTION Check each weight roller for wear or damage. Measure each weight roller O.D. Service Limit: 15.4mm replace if below Check the drive pulley collar for wear or damage.

  • Page 103: Starter Pinion

    9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Movable Drive Face INSTALLATION Install the drive pulley collar and movable drive face onto the crankshaft. Drive Pulley Collar Set the drive belt on the drive pulley collar. Install the drive pulley face and tighten the drive face nut.

  • Page 104: Clutch/Driven Pulley

    9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Clutch Outer CLUTCH/DRIVEN PULLEY REMOVAL Remove the drive pulley. ( 9-6) Hold the clutch outer with the universal holder and remove the clutch outer nut. Remove the clutch outer. Special Universal Holder Universal Holder Clutch/Driven Pulley Remove the clutch/driven pulley assembly...
  • Page 105 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Oil Seal Movable Driven Face Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. Remove the O-rings and oil seal from the movable driven face. Guide Roller Pin O-rings INSPECTION...
  • Page 106 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Check the driven face for wear or damage. Measure the driven face O.D. Service Limit: 33.94mm replace if below Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 34.06mm replace if over Inner Bearing DRIVEN PULLEY FACE BEARING...
  • Page 107 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Press a new needle bearing into the driven face. Outer Driver, 24x26mm Pilot, 17mm Movable Driven Face Oil Seal ASSEMBLY Install the movable driven face onto the driven face. Install the O-rings, guide rollers and guide roller pins.
  • Page 108 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Clutch/Driven Pulley INSTALLATION Lay the drive belt on the driven pulley and install the clutch/driven pulley onto the drive shaft. Install the clutch outer. Clutch Outer Hold the clutch outer with the universal holder.
  • Page 109 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 5.0～6.0kg-m 3.5-4.0g-m 3.5-4.5g-m...

  • Page 110: Service Information

    9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 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 • The drive pulley, clutch and driven pulley can be serviced with the engine installed. •...
  • Page 111 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 LEFT CRANKCASE COVER Left Crankcase Cover REMOVAL Loosen the drive belt air tube band screw. Remove the eight left crankcase cover bolts and left crankcase cover. Remove the seal rubber and dowel pins. Inspect the seal rubber for damage or deterioration.
  • Page 112 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Return Spring Spindle INSPECTION Inspect the kick starter spindle and gear for wear or damage. Inspect the return spring for weakness or damage. Inspect the kick starter spindle bushings for wear or damage. Plastic Bushing Spindle Bushing Inspect the starter driven gear for wear or...
  • Page 113 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Friction Spring Install the starter driven gear and friction spring onto the left crankcase cover as the figure shown. Starter Driven Gear First install the washer and then install the circlip. Install the kick lever. Washer Circlip Dowel Pins...
  • Page 114 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 DRIVE BELT REMOVAL 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 Clutch Outer REPLACEMENT Remove the eight left crankcase cover bolts and left crankcase cover.
  • Page 115 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 INSTALLATION Turn the driven pulley clockwise to widen the drive belt groove and lay a new drive belt on the driven pulley. Drive Belt Drive Belt Drive Pulley Face Drive Face Nut Set the drive belt on the drive pulley face collar.
  • Page 116 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Ramp Plate Remove the ramp plate. Weight Roller Remove the weight rollers. INSPECTION Check each weight roller for wear or damage. Measure each weight roller O.D. Service Limit: 15.4mm replace if below Check the drive pulley collar for wear or damage.
  • Page 117 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Movable Drive Face INSTALLATION Install the drive pulley collar and movable drive face onto the crankshaft. Drive Pulley Collar Set the drive belt on the drive pulley collar. Install the drive pulley face and tighten the drive face nut.
  • Page 118 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Clutch Outer CLUTCH/DRIVEN PULLEY REMOVAL Remove the drive pulley. ( 9-6) Hold the clutch outer with the universal holder and remove the clutch outer nut. Remove the clutch outer. Special Universal Holder Universal Holder Clutch/Driven Pulley Remove the clutch/driven pulley assembly...
  • Page 119 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Oil Seal Movable Driven Face Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. Remove the O-rings and oil seal from the movable driven face. Guide Roller Pin O-rings INSPECTION...
  • Page 120 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Check the driven face for wear or damage. Measure the driven face O.D. Service Limit: 33.94mm replace if below Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 34.06mm replace if over Inner Bearing DRIVEN PULLEY FACE BEARING...
  • Page 121 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Press a new needle bearing into the driven face. Outer Driver, 24x26mm Pilot, 17mm Movable Driven Face Oil Seal ASSEMBLY Install the movable driven face onto the driven face. Install the O-rings, guide rollers and guide roller pins.
  • Page 122 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SUPER8 Clutch/Driven Pulley INSTALLATION Lay the drive belt on the driven pulley and install the clutch/driven pulley onto the drive shaft. Install the clutch outer. Clutch Outer Hold the clutch outer with the universal holder.

  • Page 123: Final Reduction

    . FINAL REDUCTION SUPER8 50 10-0...

  • Page 124: Service Information

    . FINAL REDUCTION SUPER8 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 : 0.2 liter At change : 0.18 liter...

  • Page 125: Final Reduction Disassembly

    . FINAL REDUCTION SUPER8 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 126: Bearing Replacement

    . FINAL REDUCTION SUPER8 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 127: Final Reduction

    . FINAL REDUCTION SUPER8 50 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 128 . FINAL REDUCTION SUPER8 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 129 . CRANKCASE/CRANKSHAFT SUPER8 50 11-0...
  • Page 130 . CRANKCASE/CRANKSHAFT SUPER8 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. • The following parts must be removed before separating the crankcase.

  • Page 131: Crankcase/Crankshaft

    . CRANKCASE/CRANKSHAFT SUPER8 50 CRANKCASE SEPARATION Remove the cam chain tensioner slipper bolt and cam chain tensioner slipper. Cam Chain Tensioner Slipper Bolt Crankcase Bolt Remove the crankcase attaching bolt. Separate the left and right crankcase halves. ＊ • Do not damage the crankcase gasket surface.
  • Page 132 . CRANKCASE/CRANKSHAFT SUPER8 50 Clean off all gasket material from the crankcase mating surfaces. ＊ Avoid damaging the crankcase mating surfaces. Oil Seal Remove the oil seal from the left crankcase. Oil Seal Remove the oil seal from the right crankcase.

  • Page 133: Crankcase Assembly

    . CRANKCASE/CRANKSHAFT SUPER8 50 Measuring Location Measure the connecting rod big end radial clearance at two points at right angels to the shaft. Service Limit: 0.05mm replace if over Measure the crankshaft runout. Service Limit: 0.10mm replace if over Crankshaft Bearings Turn the crankshaft bearings and check for excessive play.
  • Page 134 . CRANKCASE/CRANKSHAFT SUPER8 50 Driver Handle A Outer Driver Cam Chain Install the cam chain into the left crankcase. Install the crankshaft into the left crankcase. ＊ When installing the cam chain, be careful not to damage the oil seal.
  • Page 135 . CRANKCASE/CRANKSHAFT SUPER8 50 O-ring Install the cam chain tensioner slipper. Install a new O-ring onto the cam chain tensioner slipper bolt. Apply engine oil to the O-ring and tighten the bolt. Torque: 0.8~1.2kgf-m ＊ Be sure to install the O-ring into the groove.

  • Page 136: Front Wheel/Front Brake/ Front Suspension

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 50 12-0...
  • Page 137 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 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 138 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 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 • Insufficient tire pressure •...

  • Page 139: Installation

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 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 140: Front Wheel Removal

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 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 141: Wheel Rim

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 50 WHEEL RIM Check the wheel rim runout. Service Limits: Radial: 2.0mm replace if over Axial: 2.0mm replace if over Play Turn the wheel bearings and replace the bearings if they are noisy or have excessive play.
  • Page 142 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 50 Bearing Puller Remove the front wheel bearings and distance collar. Special Bearing Puller Pilot ASSEMBLY Grease Grease Pack all bearing cavities with grease. Drive in the left bearing. Install the distance collar.
  • Page 143 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 50 Apply grease to a new dust seal lip and install Side Collar the dust seal. Install the side collar. Dust Seal 12-7...
  • Page 144 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 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 145 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 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 146: Brake Master Cylinder

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 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...
  • Page 147 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 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 148 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 50 Disassembly Brake Caliper Seat Remove the brake caliper seat from the brake caliper. Compressed Air Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet...
  • Page 149 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 50 Place the brake master cylinder on the handlebar and install the holder with “up” Punch Mark Bolts mark facing up. Be sure to align the punch mark with the holder joint. First tighten the upper bolt and then tighten the lower bolt.
  • Page 150 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 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 151 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 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 152: Front Shock Absorber

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 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 153 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 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 154: Installation

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 50 Install the damper spring onto the damper rod and then install them into the front shock absorber tube. Install the shock absorber spring onto the front shock absorber tube and tighten the top nut.

  • Page 155: Front Fork

    . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 50 Long Socket Wrench FRONT FORK 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 156 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SUPER8 50 Driver Handle A Drive new top and bottom ball races into the steering head using the outer driver. ＊ Be sure to completely drive in the ball races. Outer Driver, 37x40mm INSTALLATION...

  • Page 157: Rear Wheel /Rear Brake /Rear Suspension

    . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION SUPER8 50 1.2kg-m 11.0kg-m 3.5kg-m 13-0...

  • Page 158: Service Information

    . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION SUPER8 50 SERVICE INFORMATION ...... 13-1 REAR BRAKE.........13-3 TROUBLESHOOTING ......13-1 REAR SHOCK ABSORBER....13-4 REAR WHEEL .......... 13-2 SERVICE INFORMATION GENERAL INSTRUCTIONS • During servicing, keep oil or grease off the brake drum and brake linings.
  • Page 159 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION SUPER8 50 REAR WHEEL Rear Shock Absorber Bolt REMOVAL Remove the exhaust muffler. ( 2-5) Remove the rear axle nut and rear shock absorber bolt. Remove the rear axle side collar and rear fork.
  • Page 160 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION SUPER8 50 REAR BRAKE 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 161 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION SUPER8 50 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 162 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION SUPER8 50 Lock Nut INSPECTION Inspect the damper rod for bending or damage. Inspect the damper for oil leaks. Inspect the damper rubber for deterioration or damage. Spring Measure the rear shock absorber spring free length.
  • Page 163 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION SUPER8 50 Upper Mount Bolt INSTALLATION Install the rear shock absorber. Install the rear shock absorber upper mount bolt and then the lower mount bolt. Tighten the bolts. Torque: Upper Mount Bolt: 3.5~4.5kgf-m Lower Mount Bolt: 2.4~3.0kgf-m Install the air cleaner case.

  • Page 164: Battery/Charging System/A.c

    . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR SUPER8 50 Regulator/Rectifier Battery Fuse A.C. Generator Fuse A.C. Generator Regulator/Rectifier Battery 14-0...
  • Page 165 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR SUPER8 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...... 14-5 SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes.

  • Page 166: Specifications

    . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR SUPER8 50 SPECIFICATIONS Item Standard Capacity/Model 12V−4AH 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 0.1～1.0Ω...

  • Page 167: Battery Removal

    . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR SUPER8 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 168: Charging System

    . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR SUPER8 50 CHARGING SYSTEM Terminal 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 169 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR SUPER8 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 : Item (Wire Color)

  • Page 170: Generator Removal

    . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR SUPER8 50 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 171 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR SUPER8 50 Remove the cooling fan by removing the four cooling fan attaching bolts. Cooling Fan Universal Holder Hold the flywheel with an universal holder. Remove the flywheel nut. Special Universal Holder Remove the A.C. generator flywheel using the flywheel puller.
  • Page 172 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR SUPER8 50 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 173 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR SUPER8 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. Universal Holder...
  • Page 174 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR SUPER8 50 Install the fan cover. Install the right side cover. ( 2-4) Fan Cover 14-10...

  • Page 175: Ignition System

    . IGNITION SYSTEM SUPER8 50 CDI Unit Ignition Switch A.C. Generator Spark Plug Pulser Coil B/L1 Fuse B/L1 Ignition G/B2 G/B1 Switch Ω AUTO Light Battery REG/ CDI Unit control 15-0...

  • Page 176: Service Information

    . IGNITION SYSTEM SUPER8 50 SERVICE INFORMATION ...... 15-1 IGNITION COIL ........15-4 TROUBLESHOOTING ......15-2 PULSER COIL ........15-5 CDI UNIT INSPECTION ......15-3 SERVICE INFORMATION GENERAL INSTRUCTIONS • Check the ignition system according to the sequence specified in the Troubleshooting. ( 15-2) •...
  • Page 177 . IGNITION SYSTEM SUPER8 50 TROUBLESHOOTING High voltage too low No or intermittent high voltage • Weak battery or low engine speed • Faulty ignition coil • Loose ignition system connection • Weak battery • Faulty ignition coil • Faulty charging system •...

  • Page 178: Cdi Unit Inspection

    . IGNITION SYSTEM SUPER8 50 CDI UNIT INSPECTION Remove the two battery cover screws. Disconnect the CDI coupler and remove the CDI unit. Measure the resistance between the terminals using the electric tester. ＊ • Due to the semiconductor in circuit, it is necessary to use a specified tester for accurate testing.

  • Page 179: Ignition Coil Removal

    . IGNITION SYSTEM SUPER8 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 ＊ The CDI unit is not adjustable. If the timing is incorrect, inspect the CDI unit, pulser coil and A.C.

  • Page 180: Ignition Timing Inspection

    . IGNITION SYSTEM SUPER8 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 181: Starting System

    . STARTING SYSTEM SUPER8 50 Stop Switches Starter Relay Starter Button Starter Motor Starter Relay Ignition Switch Fuse Starter Switch Stoplight Battery Front Rear Starter Motor Stop Switches 16-0...
  • Page 182 . STARTING SYSTEM SUPER8 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 Standard (mm) Service Limit (mm) Starter motor brush length 12.5...

  • Page 183: Starter Motor

    . STARTING SYSTEM SUPER8 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 184 . STARTING SYSTEM SUPER8 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 and there should be continuity.

  • Page 185: Starter Relay Inspection

    . STARTING SYSTEM SUPER8 50 Front Cover Commutator ASSEMBLY 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.

  • Page 186: Starter Motor Installation

    . STARTING SYSTEM SUPER8 50 STARTER RELAY TEST Starter Relay Remove the battery cover. Disconnect the 4P connector from the starter relay and 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 187: Lights/Instruments/Switches

    . LIGHTS/INSTRUMENTS/SWITCHES SUPER8 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 188: Installation

    . LIGHTS/INSTRUMENTS/SWITCHES SUPER8 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 189: Handlebar Switches

    . LIGHTS/INSTRUMENTS/SWITCHES SUPER8 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 Color Black Brown Blue/...

  • Page 190: Ignition Switch

    . LIGHTS/INSTRUMENTS/SWITCHES SUPER8 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. IGNITION SWITCH INSPECTION Remove the front covers.

  • Page 191: Stop Switch

    . LIGHTS/INSTRUMENTS/SWITCHES SUPER8 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 192: Headlight Removal

    . LIGHTS/INSTRUMENTS/SWITCHES SUPER8 50 HEADLIGHT REMOVAL Front Cover Bolts Screw Remove the screw on the front cover. Remove the two screws on the back of the front cover. Remove the front cover. Remove the two bolt and twelve screws attaching the R/L mole side.

  • Page 193: Exhaust Emission Control

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM SUPER8 50 EXHAUST EMISSION CONTROL SYSTEM DIAGRAM ...........18-0 EXHAUST EMISSION CONTROL SYSTEM ...............18-1 SERVICE INFORMATION.....................18-1 TROUBLESHOOTING ......................18-1 MAINTENANCE SCHEDULE ....................18-2 SECONDARY AIR CLEANER....................18-3 AIR INJECTION CUT-OFF VALVE (A.I.C.V.) ..............18-4 REED VALVE .........................18-5 EXHAUST MUFFLER ......................18-6 EXHAUST EMISSION RELATED SYSTEM INSPECTION..........18-7...

  • Page 194: Evaporative/Exhaust Emission Control System Super8

    . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM SUPER8 50 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 195 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM SUPER8 50 MAINTENANCE SCHEDULE: (1) PERIODIC MAINTENANCE Service Mileage 300 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 Item Engine oil Oil filter screen Gear oil Motor oil filter...

  • Page 196: Ignition System

    . IGNITION SYSTEM SUPER8 50 Met-in Box Center Coverl SECONDARY AIR CLEANER REMOVAL Remove the met-in box. ( 2-3) Remove the center cover. ( 2-3) Remove the frame body covers. ( 2-4) Remove the floor board. ( 2-4) Floor Board...
  • Page 197 . IGNITION SYSTEM SUPER8 50 Air Injection Cut-off Valve AIR INJECTION CUT-OFF VALVE Vacuum Pump INSPECTION Inspect the air injection cut-off valve flow using a vacuum pump. If the flow is not within the specified values, replace with a new one.

  • Page 198: Reed Valve

    . IGNITION SYSTEM SUPER8 50 Cylinder Head Cover Bolts REED VALVE REMOVAL Remove the met-in box and frame center cover. Disconnect the secondary air inlet tube connector. Remove the four cylinder head cover bolts and two secondary air outlet tube bolts.

  • Page 199: Exhaust Muffler

    . IGNITION SYSTEM SUPER8 50 Exhaust Muffler Joint Lock Nut EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts and two exhaust muffler lock bolts. Remove the exhaust muffler. ＊ • The temperature of exhaust muffler is very high. Be careful to avoid burns during working.

  • Page 200: Exhaust Emission Related System Inspection

    . IGNITION SYSTEM SUPER8 50 EXHAUST EMISSION RELATED SYSTEM INSPECTION Clean or replace the air cleaner. ( 3-4) Clean and adjust the carburetor. ( 3-5) Inspect the auto bystarter system. ( 5-4) Clean and inspect the spark plug. ( 3-4) Inspect the ignition system.

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