KYMCO Super 8 50 Manuals

Manuals and User Guides for KYMCO Super 8 50. We have 4 KYMCO Super 8 50 manuals available for free PDF download: Service Manual, Owner's Manual, Manual

KYMCO Super 8 50 Service Manual (186 pages)

Brand: KYMCO | Category: Scooter | Size: 15 MB

Table of Contents
1
Super
2
Engine Serial Number
2
General Information
2
Specifications
3
Service Precautions
4
- Symbols
  11
- Standard Torque Values
  12
- Frame
  12
Torque Values
12
Special Tools
13
Lubrication Points
14
Cable & Harness Routing
16
Wiring Diagram
19
- Engine will Not Start or Is Hard to Start
  20
- Troubleshooting
  20
- Engine Lacks Power
  21
- Poor Performance at Low and Idle Speed
  23
- Poor Performance at High Speed
  24
- Poor Handling
  24
- Schematic Drawing
  25
- Frame Covers/Exhaust Muffler
  26
- Service Information
  28
- General Instructions
  28
- Items Related for Removal
  28
Frame Covers/Exhaust Muffler
28
- Frame Covers
  29
- Front Cover Removal
  29
- Handlebar Front Cover Removal
  29
- Handlebar Rear Cover Removal
  29
- Frame Body Cover Removal
  30
- Floor Board Removal
  32
- Front Fender and under Cowl Removal
  32
- Exhaust Muffler Removal
  33
- Inspection/Adjustment
  34
- Tire Pressure
  35
- Tire Size
  35
- Fuel Filter
  36
- Maintenance Schedule
  36
- Throttle Operation
  37
- Air Cleaner
  38
  - Air Cleaner Replacement
    38
  - Change Interval
    38
- Spark Plug
  38
- Valve Clearance
  39
- Cylinder Compression
  40
- Ignition Timing
  40
Inspection/Adjustment
40
- Valve Clearance
  40
- Drive Belt
  41
- Final Reduction Gear Oil
  41
  - Oil Change
    41
  - Oil Level Check
    41
- Super 8
  41
- Clutch Shoe Wear
  42
- Headlight Aim
  42
  - Rear Suspension
    42
  - Suspension Front
    42
- Nuts/Bolts/Fasteners
  43
- Steering Handlebar
  43
- Wheels/Tires
  43
Lubrication System
44
- Lubrication System
  45
  - Oil Level too Low
    45
  - Poor Lubrication Pressure
    45
- Service Information
  45
- Troubleshooting
  45
- Engine Oil/Oil Filter
  46
  - Oil Level
    46
  - Oil Pump Removal
    46
  - Fuel Injection System
    51
- System Diagram
  52
- Parts Location
  53
- Service Information
  54
- Troubleshooting
  55
- Check Engine Lamp (Celp)
  56
- How to Show the Failure Code
  57
  - Failure Code Chart
    58
  - Failure Code
    59
- Ecu
  62
- Voltage Inspection
  62
- Fuel Pump
  63
  - Enter the Data Analyze
    64
  - T-MAP Sensor
    64
  - TPS (Throttle Position Sensor)
    64
  - ETS (Engine Temperature Sensor)
    65
- Injector
  65
- Wts
  65
- O2 Sensor
  66
- Roll Sensor
  67
- Tp Screw
  67
- TPI / ABV Initialization
  68
- Diagnostic Report
  69
- Fi Diagnostic Tool
  70
- Dtc Inspection
  71
- Dtc Clear Procedure
  74
- Data Analysis
  75
- Adjust
  77
- Engine Removal/Installation
  78
Engine Removal/Installation
80
- Engine Hanger Bracket Installation
  82
- Engine Installation
  82
Cylinder Head/Valves
83
- Compression too High
  85
- White Smoke from Exhaust Muffler
  85
- Compression too Low
  85
- Poor Performance at Idle Speed
  85
- Camshaft Removal
  86
- Camshaft Holder Disassembly
  88
- Camshaft Holder Inspection
  88
- Cylinder Head Remove
  89
- Cylinder Head Disassembly
  90
- Valve Spring Compressor
  90
- Cylinder Head Inspection
  90
- Valve Spring Free Length
  90
- Valve /Valve Guide
  91
- Cylinder Head Assembly
  91
- Camshaft Holder Assembly
  92
- Cylinder Head Installation
  92
- Camshaft Installation
  93
Cylinder/Piston
95
- Compression too Low or Uneven Compression
  96
- Excessive Smoke from Exhaust Muffler
  96
- Abnormal Noisy Piston
  96
- Cylinder Removal
  97
- Piston Removal
  97
- Cylinder Inspection
  99
- Piston Ring Installation
  100
- Piston Installation
  101
- Cylinder Installation
  101
Drive and Driven Pulleys
103
- Lack of Power
  104
- Engine Starts but Motorcycle Won‘t Move
  104
- Engine Stalls or Motorcycle Creeps
  104
- Left Crankcase Cover
  105
- Drive Pulley
  106
- Clutch/Driven Pulley
  110
- Clutch Spring Compressor
  111
- Driven Pulley Face Bearing
  113
- Clutch Disassembly
  114
- Clutch Assembly
  114
- Clutch/Driven Pulley Assembly
  114
Final Reduction
117
- Abnormal Noise
  118
- Oil Leaks
  118
- Final Reduction Disassembly
  119
- Final Reduction Inspection
  119
- Bearing Replacement
  120
- Bearing Puller
  121
- Final Reduction Assembly
  121
Crankcase/Crankshaft
123
- Excessive Engine Noise
  124
- Crankcase Separation
  125
- Crankshaft Inspection
  126
- Crankcase Assembly
  127
Front Wheel/Front Brake/ Front Suspension
129
- Front Shock Absorber Noise
  131
- Soft Front Shock Absorber
  131
- Front Wheel Wobbling
  131
- Hard Steering (Heavy)
  131
- Steering Handlebar
  132
- Front Wheel
  133
- Wheel Rim
  134
- Hydraulic Brake (Front Brake)
  136
- Brake Fluid Replacement/Air Bleeding
  136
- Brake Fluid Bleeding
  136
- Brake Fluid Refilling
  136
- Brake Pad/Disk Replacement
  137
- Brake Disk
  137
- Brake Master Cylinder
  138
- Brake Caliper (Front)
  141
- Front Shock Absorber
  144
- Front Fork
  147
- Long Socket Wrench,32Mm 8Angle
  147
- Bottom Cone Race Replacement
  147
- Ball Race Replacement
  147
Rear Wheel/Rear Brake/Rear
149
- Rear Shock Absorber Removal
  151
- Rear Wheel Removal
  151
- Rear Brake Removal
  152
- Brake Lining Inspection
  152
- Rear Brake Disassembly
  152
- Rear Brake Assembly
  152
- Battery/Charging System/A.C Generator
  154
- No Power
  156
- Low Power
  156
- Intermittent Power
  156
- Charging System Failure
  156
- Battery Voltage (Open Circuit Voltage) Inspection
  157
- Short Circuit Test
  158
- Current Test
  158
- Regulator/Rectifier
  159
- Main Harness Circuit Inspection
  159
- A.C. Generator Charging Coil
  160
- A.C. Generator
  160
- A.C. Gnerator Installation
  162
Ignition System
165
- No Peak Voltage
  167
- Peak Voltage Is Normal, but no Spark Jumps at the Plug
  167
- Ignition Coil
  168
- Continuity Test
  168
- Pulser Coil
  169
- Ignition Timing Inspection
  169
- Timing Hole Cap
  169
- A .C. Generator Inspection
  170
- Crank Position Sensor Inspection
  170
- Angle Detect Sensot
  170
Starting System
172
- Starter Motor Rotates but Engine Does Not Start
  173
- Starter Motor Won‘t Turn
  173
- Starter Motor Case Continuity Check
  175
- Starter Relay
  176
- Operation Test
  177
- Starter Clutch
  177
- Starter Relay Ground Circuit Inspection
  177
- Clutch Body Disassembly
  178
- Flywheel Holder
  178
- Starter Clutch Disassembly
  178
- Fuel Gauge Pointer Does Not Register Correctly
  180
- Light Dims
  180
- Troubleshooting
  180
- Fuel Unit
  181
Lights Do Not Come on When Ignition Switch Is “ON”
180
Lights/Instruments/Switches
180
- Fuel Gauge Inspection
  181
- Dimmer Switch
  182
- Handlebar Switches
  182
  - Headlight Switch
    182
  - Starter Switch
    182
  - Horn Switch
    183
- Ignition Switch
  183
  - Ignition Switch Replacement
    183
  - Switch Replacement
    183
  - Horn
    184
- Instruments
  184
- Stop Switch
  184
- Headlight
  185
- Bulb Replacement
  185

KYMCO Super 8 50 Service Manual (99 pages)

Brand: KYMCO | Category: Scooter | Size: 12 MB

Preface

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

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

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

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

KYMCO Super 8 50 Owner's Manual (56 pages)

KYMCO Super 8 Motor Scooter Owner's manual

Brand: KYMCO | Category: Scooter | Size: 4 MB

Table of Contents
3
Section 1 - Safety

4
- Foreword
  4
- Scooter Safety
  5
- Section 1 - Safety
  5
- Load Limits & Guidelines
  7
- Accessories & Modifications
  8
Section 2 - Controls & Features

9
- Locations of Parts & Controls
  9
- Keys
  10
- Ignition Switch & Steering Lock
  10
- Right-Hand Handlebar Switch
  11
- Engine-Stop Switch
  11
- Electric Start Button
  11
- Left-Hand Handlebar Switch
  12
- Headlight Dimmer Switch
  12
- Turn Signal Switch
  12
- Under-Seat Storage Compartment
  13
- Helmet Posts
  13
- Main Stand
  14
- Instruments
  14
- Passenger Pegs
  15
- Section 2 - Controls & Features
  15
Section 3 - Operation

16
- Break-In Recommendations
  16
- Tire Break-In
  17
- Troubleshooting
  17
- Pre-Ride Inspection
  18
- Engine Oil Inspection
  19
- Brake Lever Free-Play Inspection
  19
- Tire Inspection
  20
- Fuel Level / Filler Cap
  21
- Fuel Recommendation
  21
- Steering & Handlebar Inspection
  22
- Instrument Inspection
  22
- Brake Adjustment & Pad Inspection
  23
- Horn & Lights Inspection
  24
- Chassis Inspection
  25
- Starting the Engine (Electric Start)
  26
- Starting the Engine (Kick Start)
  27
- Riding Your Scooter
  28
- Riding Your Scooter
  31
- Parking Your Scooter
  32
- Section 3 - Operation
  32
Section 4 - Maintenance

33
- Importance of Maintenance
  33
- Maintenance Schedule
  34
  - Section 4 - Maintenance
    34
  - Maintenance Schedule
    35
- Tires
  36
- Tire Pressure
  36
- Air Filter Maintenance
  37
- Fuel Hoses
  38
- Battery
  38
- Fuses
  39
  - Battery
    39
  - Fuse Replacement
    39
- Engine Oil
  40
- Engine Oil Level Inspection & Change
  40
- Transmission Fluid Inspection & Change
  42
- Spark Plug
  43
- Brake Fluid Level Inspection
  43
- Cleaning Your Scooter
  44
- Storage
  46
- Maintenance Record
  47
- Specifications (50 Model)
  48
- Specifications (150 Model)
  49
- Exhaust Emission Control System
  50
- Emission Information & EPA Warranty
  52
- Crankcase Emission Control System
  52
- KYMCO Limited Scooter Warranty
  53
- Index
  54
- Identification Numbers Record
  55

KYMCO Super 8 50 Manual (51 pages)

Brand: KYMCO | Category: Scooter | Size: 15 MB

Identification Numbers Record
3
Table of Contents
4
Section 1-Safety Introduction
5
Forward
5
Scooter Safety
6
Important Safety Information
6
Protective Clothing
7
Accessories & Modifications
8
Locations of Parts & Controls
9
Section 2-Controls & Features
12
Section 2 - Controls&Features
12
Ignition Switch
12
Instruments
13
Passenger Foot Pegs
17
Right-Hand Handlebar Switch
18
Left-Hand Handlebar Switch
19
Fuel Recommendation
20
Fuel Tank
20
Seat
21
Helmet Holder and Hook
22
Suspension
23
Section 3-Operation
24
Pre-Ride Inspection
24
Break-In
25
Starting the Engine
26
Section 4-Maintenance
28
Maintenance Schedule
28
Engine Oil
32
Engine Oil Replacement
33
Transmission Fluid Change
34
Air Filter Element Change
35
Throttle Operation
36
Spark Plug
37
Brake Fluid Level Inspection
38
Brake Pad Inspection
39
Brake Lever Free Play Inspection & Adjustment
40
Battery
41
Fuse
42
Tires
43
Tires Inspection
44
Tire Size, Front
44
Tire Size, Rear
44
Clean the Vehicle
45
Crankcase Blow-By Drain
46
Storage
47
Emission Control
48
Maintenance Record
49
Specifications
51
Brake (Front)
51
Brake (Rear)
51

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