KYMCO SUPER8 50 User manual

UPER8 50

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.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

TABLE OF CONTENTS

GENERAL INFORMATION

FRAME COVERS/EXHAUST MUFFLER

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

FUEL SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/VALVES

CYLINDER/PISTON

ENGINE

DRIVE AND DRIVEN PULLEYS/KIC

STARTER

FINAL REDUCTION

CRANKCASE/CRANKSHAFT

FRONT WHEEL/FRONT BRAKE/

FRONT SUSPENSION

CHASSIS

REAR WHEEL /REAR BRAKE /REAR

SUSPENSION

BATTERY/CHARGING SYSTEM/A.C.

GENERATOR

IGNITION SYSTEM

STARTING SYSTEM

LIGHTS/INSTRUMENTS/SWITCHES

ELECTRICAL

EQUIPMEN

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

SUPER8 50

Location of Engine Serial Numbe

Frame Serial Numbe

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

SUPER8 50

SPECIFICATIONS

Motorcycle Name & Type SUPER8 50

Name & Model No. LEJ2

Overall length (mm) 1940

Overall width (mm) 745

Overall height (mm) 1220

Wheel base (mm) 1365

Engine type O.H.C.

Displacement 50cc

Fuel Used 92# nonleaded gasoline

Front wheel 43

Net weight (kg) Rear wheel 55

Total 108

Front wheel 45

Gross weight(kg) Rear wheel 67

Total 144

Front wheel 100/80 -14 56J

Tires Rear wheel 120/80 -14 56J

Ground clearance (mm) 112

Perform- Braking distance (m) 4 (Initial speed

20km/h)

ance Min. turning radius (m) 1.99

Starting system Starting motor &

kick starter

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement O.H.C.

Bore x stroke (mm) φ39.0 x 41.4

Compression ratio 11

Compression pressure

(kg/cm²-rpm) 18

Max. output 2.4/7500kw/(r/min)

Max. torque 3.2/7000kg m/rpm

Open 3°

Port Intake Close 7°

Engine

timin

Open 9°

Exhaust Close 1°

Valve

clearance Intake 0.08

(cold) (mm) Exhaust 0.08

Idle speed (rpm) 1900±100rpm

Lubrication type Forced

ressure &

wet sump

Oil pump type Inner/outer rotor type

Oil filter type Full-flow filtration

Lubrication

System

Oil capacity 0.8 liter

Cooling Type Forced air cooling

Air cleaner type & No Paper element, wet

Fuel capacity 6.0 liter

Type CVK

Piston dia. (mm) 18

Venturi dia.(mm) φ18.5equivalent

Carburetor

Throttle type Butterfly type

Type CDI

Ignition timing BTDC28°/4000rpm

Contact breaker Non-contact point type

Spark plug NGK CR7HSA

Spark plug gap 0.6～0.7mm

Battery Capacity 12V7AH

Clutch Type Dry multi-disc clutch

Type Non-stage transmission

Operation Automatic centrifugal

type

Type Two-stage reduction

Reduction 1st 0.8-3.1

ratio 2nd 11.05

Front Caster angle 27°

Axle Trail length ⎯

Tire

ressure Fron

1.75

(kg/cm²)Rear 2.25

Turning Left 45°

angle Right 45°

Fron

DISK

(

180mm

)

brake

Brake system

type Rear Drum (110mm) brake

Fron

TELESCOPE

Suspension type Rear Unit Swing

Front 80

Shock absorber

distance Rear 82

Frame type Under Bone

Fuel S

stem Electrical Equipment

nition S

stem

Power Drive System

Transmis-

sion Gear Reduction

Gear

Moving Device Damping

Device

1. GENERAL INFORMATION

1-3

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.

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

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.

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

SUPER8 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.

Confir

Capacity

1. GENERAL INFORMATION

1-6

SUPER8 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.

Sna

1. GENERAL INFORMATION

1-7

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.

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.

o Contact !

1. GENERAL INFORMATION

1-8

SUPER8 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 ti

ht!

Do not press o

ueeze the wire.

1. GENERAL INFORMATION

1-9

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.

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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