KYMCO SUPER8 50 Service Manual
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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
SUPER8 50

TABLE OF CONTENTS

FINAL REDUCTION
CRANKCASE/CRANKSHAFT
FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
REAR WHEEL /REAR BRAKE /REAR
SUSPENSION
BATTERY/CHARGING SYSTEM/A.C.
GENERATOR
IGNITION SYSTEM
STARTING SYSTEM
LIGHTS/INSTRUMENTS/SWITCHES
EXHAUST EMISSION CONTROL
SYSTEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

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  • 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 . 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 . 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 . 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 Worn camshaft Incorrectly adjusted...
  • 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: Frame Covers/Exhaust Muffler

    . 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 . 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 . 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:...

  • 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 Fluid

    . 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 . 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: Lubrication System

    . 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 . 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

    . 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 . 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 valve seat must be replaced because it will result in float level too high due to incomplete airtightness.

  • 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 Tank

    . 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 SUPER8 50...
  • Page 71 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 Installation

    . 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: Cylinder Head/Valves

    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: Troubleshooting

    . 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 . 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 CYLINDER HEAD ASSEMBLY Valve Spring Compressor •...

  • 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 . 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

    . CYLINDER/PISTON SUPER8 50 1.0kg-m Do not bend...
  • Page 88 . 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/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 . 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. • Position the piston “IN” mark on the intake valve side.
  • 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 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: Drive And Driven Pulleys/Kick Starter

    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: Kick Starter

    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 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...

This manual is also suitable for:

Super 8 50

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