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KYMCO SUPER8 50 2T User Manual

KYMCO SUPER8 50 2T
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1.SPECIFICATIONS
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SUPER8 50 2T
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TABLE OF CONTENTS
SPECIFICATIONS................................................................................ 1
GENERAL INFORMATION.................................................................. 2
INSPECTION/ADJUSTMENT .............................................................. 3
LUBRICATION SYSTEM ..................................................................... 4
ENGINE REMOVAL/INSTALLATION.................................................. 5
CYLINDER HEAD/CYLINDER/PISTON............................................... 6
A.C. GENERATOR............................................................................... 7
KICK STARTER/DRIVE PULLEY/CLUTCH/DRIVEN PULLEY........... 8
FINAL REDUCTION............................................................................. 9
CRANKCASE/CRANKSHAFT.............................................................10
CARBURETOR ....................................................................................11
FRAME COVERS.................................................................................12
STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/
FRONT SHOCK ABSORBER/FRONT FORK .....................................13
REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER ..............14
ELECTRICAL EQUIPMENT.................................................................15
INSTRUMENT/SWITCHES/LIGHTS....................................................16
EXHAUST EMISSION CONTROL SYSTEM........................................17

Table of Contents

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KYMCO SUPER8 50 2T Specifications

General IconGeneral
Engine Type2-stroke, single cylinder
Fuel SystemCarburetor
TransmissionCVT automatic
Front SuspensionTelescopic fork
Rear SuspensionSingle Shock
Front BrakeDisc
Rear BrakeDrum
Front Tire120/70-12
Rear Tire130/70-12
Seat Height780 mm
IgnitionCDI
StarterElectric & Kick
Width700 mm
Cooling SystemAir-cooled

Summary

Specifications

General Information

Engine Serial Number and Identification

Details about engine serial number and identification.

Service Precautions

Important precautions for servicing the motorcycle.

Service Information

General service information and specifications for engine parts.

Torque Values

Specifications for tightening torque of various fasteners.

Special Tools

List of specialized tools required for servicing.

Lubrication Points

Identifies lubrication points for engine and frame components.

Wiring Diagram

Electrical wiring diagram for the motorcycle.

Cable and Harness Routing

Guidelines for routing cables and harnesses on the motorcycle.

Troubleshooting

Diagnostic guide for common engine starting and running issues.

Inspection and Adjustment

Inspection and Maintenance Schedule

Schedule for regular inspection and maintenance of motorcycle parts.

Moving Device

Inspection of tires, wheels, and related components.

Brake System

Procedures for inspecting and adjusting the brake system.

Damping Device

Inspection of shock absorbers and suspension components.

Power Drive System

Inspection of the transmission case and gear oil.

Electrical Equipment

Inspection and testing of ignition apparatus and related components.

Engine

Inspection and adjustment of engine components like idle speed and air cleaner.

Fuel System

Inspection and adjustment of the throttle grip free play.

Lubrication System

Service Information

General instructions, specifications, and troubleshooting for the lubrication system.

Oil Pump Removal

Step-by-step procedure for removing the oil pump.

Oil Pump Inspection

Guidelines for inspecting the oil pump for wear and damage.

Oil Pump Installation

Steps for correctly installing the oil pump and related components.

Oil Pump Bleeding

Procedures for bleeding air from the oil pump and lines.

Oil Tank

Instructions for removing and installing the oil tank.

Engine Removal and Installation

Service Information

General instructions and torque values for engine removal and installation.

Engine Removal

Detailed steps for removing the engine from the motorcycle.

Engine Installation

Procedures for reinstalling the engine and performing post-installation checks.

Cylinder Head, Cylinder, and Piston

Service Information

General instructions, specifications, and troubleshooting for cylinder head, cylinder, and piston.

Cylinder Head

Procedures for removing and installing the cylinder head.

Cylinder and Piston

Steps for removing, inspecting, and installing the cylinder and piston.

AC Generator

Service Information

General instructions and torque values for AC generator maintenance.

AC Generator Removal

Step-by-step guide for removing the AC generator components.

AC Generator Installation

Procedures for installing the AC generator and related parts.

Kick Starter, Drive Pulley, Clutch, and Driven Pulley

Service Information

General instructions, specifications, and troubleshooting for clutch and drive pulley systems.

Kick Starter

Procedures for removing, inspecting, and installing the kick starter mechanism.

Drive Belt

Instructions for inspecting and replacing the drive belt.

Drive Pulley

Procedures for removing, disassembling, and installing the drive pulley.

Clutch and Driven Pulley

Steps for removing, disassembling, and inspecting the clutch/driven pulley.

Final Reduction System

Service Information

Specified oil, special tools, and troubleshooting for the final reduction system.

Final Reduction Disassembly

Steps for disassembling the final reduction gears and related parts.

Final Reduction Inspection

Procedures for inspecting gears, shafts, and bearings for wear.

Bearing Replacement

Instructions for replacing bearings in the transmission case and left crankcase.

Final Reduction Assembly

Steps for assembling the final reduction components and case.

Crankcase and Crankshaft

Service Information

General instructions, specifications, and troubleshooting for crankcase and crankshaft service.

Crankcase Separation

Steps for separating the crankcase halves.

Crankshaft Removal

Procedure for removing the crankshaft from the crankcase.

Crankshaft Inspection

Methods for inspecting crankshaft clearances and runout.

Crankshaft Installation

Steps for installing the crankshaft and bearings.

Crankcase Assembly

Procedures for assembling the crankcase halves and oil seals.

Carburetor Service

Service Information

General instructions, specifications, and troubleshooting for the carburetor.

Throttle Valve Disassembly

Steps for disassembling the throttle valve mechanism.

Throttle Valve Installation

Procedures for reinstalling the throttle valve and related parts.

Carburetor Removal

Instructions for removing the carburetor from the motorcycle.

Auto Bystarter

Inspection and removal/installation of the auto bystarter component.

Float Chamber

Procedures for removing and disassembling the float chamber.

Float and Float Valve Inspection

Inspecting the float, float valve, and carburetor passages.

Float Level Inspection

Measuring and adjusting the float level.

Carburetor Installation

Steps for installing the carburetor and performing adjustments.

Air Screw Adjustment

Procedure for adjusting the air screw for idle speed.

Reed Valve

Instructions for removing, inspecting, and installing the reed valve.

Frame Covers

Service Information

General instructions for removing frame covers.

Frame Covers Removal/Installation

Detailed steps for removing and installing various frame covers.

Exhaust Muffler Removal

Procedure for removing the exhaust muffler.

Steering, Front Wheel, Brake, and Suspension

Service Information

General instructions and specifications for front wheel, brake, and fork systems.

Front Wheel

Procedures for removing, inspecting, and replacing front wheel bearings.

Front Hydraulic Brake

Steps for replacing brake fluid, bleeding, and replacing brake pads.

Brake Disk

Measuring brake disk thickness and runout.

Brake Master Cylinder

Procedures for removing, disassembling, inspecting, and assembling the brake master cylinder.

Front Brake Caliper

Instructions for removing, disassembling, and assembling the front brake caliper.

Front Shock Absorber

Steps for removing, inspecting, and installing the front shock absorbers.

Steering Handlebar

Procedures for removing the handlebar and related components.

Steering Stem

Steps for removing and replacing steering stem components and bearings.

Rear Wheel, Brake, and Shock Absorber

Service Information

Specifications, torque values, and troubleshooting for rear wheel, brake, and shock absorber.

Rear Wheel

Procedures for removing, inspecting, and installing the rear wheel.

Rear Brake

Instructions for inspecting brake drum, linings, and disassembling/assembling the rear brake.

Rear Shock Absorber

Steps for removing and installing the rear shock absorber.

Electrical Equipment

Service Information

General instructions, specifications, and troubleshooting for electrical components.

Charging System

Inspection and testing of the AC generator and charging system.

Battery

Procedures for removing, charging, and inspecting the battery.

Ignition System

Inspection and testing of the ignition coil, CDI unit, and related components.

Starting System

Inspection and removal/installation of the starter motor and starter relay.

Instruments, Switches, and Lights

Service Information

General instructions for connecting wires and checking switches.

Troubleshooting

Common issues with lights, oil meter, fuel gauge, and switches.

Fuel Unit

Procedures for removing, inspecting, and installing the fuel unit.

Oil Meter

Inspection and operation check of the oil meter and indicator light.

Switches

Inspection and replacement of ignition, dimmer, turn signal, starter, horn, and stop switches.

Instrument and Headlight

Procedures for replacing instrument bulbs and the headlight bulb.

Exhaust Emission Control System

Schematic Drawing

Diagram illustrating the exhaust emission control system components.

Exhaust Emission Control System

Explanation of the system's function and components.

Troubleshooting

Diagnostic guide for common exhaust emission control system issues.

Secondary Air Cleaner and AICV

Procedures for removing, inspecting, and installing the secondary air cleaner and AICV.

Reed Valve

Instructions for removing, inspecting, and installing the reed valve.

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