KYMCO Super 8 50 User manual

Super 8 50

PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO

SUPER 8 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.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

TABLE OF CONTENTS

GENERAL INFORMATION

FRAME COVERS/EXHAUST MUFFLER

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

ENGINE

FUEL SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/VALVES

CYLINDER/PISTON

DRIVE AND DRIVEN PULLEYS

FINAL REDUCTION

CRANKCASE/CRANKSHAFT

CHASSIS

FRONT WHEEL/FRONT BRAKE/

FRONT SUSPENSION

REAR WHEEL /REAR BRAKE /REAR

SUSPENSION

ELECTRICAL

EQUIPMENT

BATTERY/CHARGING SYSTEM/A.C.

GENERATOR

IGNITION SYSTEM

STARTING SYSTEM

LIGHTS/INSTRUMENTS/SWITCHES

EXHAUST EMISSION CONTROL

SYSTEM

Our company reserves the right to make

any alteration in the design.The

information and contents included in

this manual may be different from the

motorcycle in case specifications are

changed.

1. GENERAL INFORMATION

1-1

SUPER 8 50

Location of Engine Serial Number

Frame Serial Number

ENGINE SERIAL NUMBER

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

1. GENERAL INFORMATION

1-2

SUPER 8 50

SPECIFICATIONS

Motorcycle Name & Type

SUPER 8 50

Name & Model No.

KP10BA(AAB6)

Overall length (mm)

2040

Overall width (mm)

740

Overall height (mm)

1140

Wheel base (mm)

1365

Engine type

Air cooled 4-stroke

Displacement

50cc

Fuel Used

92# nonleaded gasoline

Front wheel

Net weight (kg)

Rear wheel

Total

112

Front wheel

861

Max weight(kg)

Rear wheel

176

Total

262

Tires

Front wheel

120/70 -14

Rear wheel

120/80 -14

Ground clearance (mm)

130

Perform-

Brakingdistance (m)

2.0 (Initial speed

30km/h)

ance

Min. turning radius

(mm)

L:2060/R:2050

Starting system

Starting motor

Type

Gasoline, 4-stroke

Cylinder arrangement

Single cylinder

Combustionchamber type

Semi-sphere

Valve arrangement

O.H.C.

Bore x stroke (mm)

∮39*41.4

Compression ratio

10.5

Compression pressure

(kg/cm²-rpm)

16±2

Max. output

2.4kw/7500rpm

Engine

Max. torque

3.2NM/6000rpm

Intake

Open

-4

Port

12

timing

Exhaust

Open

20

-8

Valve clearance

Intake

0.04

(cold) (mm)

Exhaust

0.04

Idle speed (rpm)

2000rpm

Lubricatio

n System

Lubrication type

OIL PUMP

Oil pump type

Cycloid type

Oil filter type

Full-flow filtration

Oil capacity

0.7 liter

Cooling Type

Forced air cooling

Air cleaner type & No

Paper element

Fuel capacity

6.0 liter

Carburetor

Type

-----

Piston dia. (mm)

------

Venturi dia.(mm)

Throttle type

Type

ECU

Ignition timing

BTDC 13°~ 28°

Contact breaker

Non-contact point type

Spark plug

NGK CR7HSA

Spark plug gap

0.6～0.7mm

Battery

Capacity

12V8AH

Clutch

Type

Dry centrifugal type

Type

CVT

Operation

Stepless automatic

transmission

Type

Two-stage reduction

Reduction

1st

0.8-3.1

ratio

2nd

11.05

Front

Caster angle

27

Axle

Trail length



Tire pressure

Front

1.75

(kg/cm²)

Rear

2.25

Turning

Left

45

angle

Right

45

Brake system

type

Front

DISK

Rear

Drum

Suspension type

Front

FR:TELESCOPE

Rear

RR:UNIT SWING

Shock absorber

distance

Front

Rear

Frame type

Pipe Under Bone

Fuel System

Electrical Equipment

Ignition System

Power Drive System

Transmis-

sion Gear

Reduction

Gear

Moving Device

Damping

Device

1. GENERAL INFORMATION

1-3

SUPER 8 50

SERVICE PRECAUTIONS

Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when

reassembling.

When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several

times, and tighten to the specified torque

diagonally.

Use genuine parts and lubricants

When servicing the motorcycle, be sure to

use special tools for removal and

installation.

After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil

before reassembly.

1. GENERAL INFORMATION

1-4

SUPER 8 50

Apply or add designated greases and

lubricants to the specified lubrication

points.

After reassembly, check all parts for proper

tightening and operation.

When two persons work together, pay

attention to the mutual working safety.

Disconnect the battery negative (-) terminal

before operation.

When using a spanner or other tools, make

sure not to damage the motorcycle surface.

After operation, check all connecting points,

fasteners, and lines for proper connection

and installation.

When connecting the battery, the positive

(+) terminal must be connected first.

After connection, apply grease to the

battery terminals.

Terminal caps shall be installed securely.

1. GENERAL INFORMATION

1-5

SUPER 8 50

If the fuse is burned out, find the cause and

repair it. Replace it with a new one

according to the specified capacity.

After operation, terminal caps shall be

installed securely.

When taking out the connector, the lock on

the connector shall be released before

operation.

Hold the connector body when connecting

or disconnecting it.

Do not pull the connector wire.

Check if any connector terminal is bending,

protruding or loose.

Confirm

Capacity

1. GENERAL INFORMATION

1-6

SUPER 8 50

The connector shall be inserted

completely.

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.

Check the double connector cover for

proper coverage and installation.

Insert the terminal completely.

Check the terminal cover for proper

coverage.

Do not make the terminal cover opening

face up.

Secure wire harnesses to the frame with

their respective wire bands at the

designated locations.

Tighten the bands so that only the insulated

surfaces contact the wire harnesses.

Snapping!

1. GENERAL INFORMATION

1-7

SUPER 8 50

After clamping, check each wire to make

sure it is secure.

Do not squeeze wires against the weld or

its clamp

After clamping, check each harness to

make sure that it is not interfering with any

moving or sliding parts.

When fixing the wire harnesses, do not

make it contact the parts which will

generate high heat.

Route wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of

bolts and screws.

Route wire harnesses passing through the

side of bolts and screws. Avoid the

projected ends of bolts and screws.

No Contact !

1. GENERAL INFORMATION

1-8

SUPER 8 50

Route harnesses so they are neither

pulled tight nor have excessive slack.

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.

Do not break the sheath of wire.

If a wire or harness is with a broken sheath,

repair by wrapping it with protective tape

or replace it.

When installing other parts, do not press or

squeeze the wires.

Do not pull

too tight!

Do not press or

squeeze the wire.

1. GENERAL INFORMATION

1-9

SUPER 8 50

After routing, check that the wire harnesses

are not twisted or kinked.

Wire harnesses routed along with handlebar

should not be pulled tight, have excessive

slack or interfere with adjacent or

surrounding parts in all steering positions.

When a testing device is used, make sure to

understand the operating methods

thoroughly and operate according to the

operating instructions.

Be careful not to drop any parts.

When rust is found on a terminal, remove

the rust with sand paper or equivalent

before connecting.

Do not bend or twist control cables.

Damaged control cables will not operate

smoothly and may stick or bind.

Do you understand

the instrument? Is

the instrument set

correctly?

Remove Rust !

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