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KYMCO Super 8 50, Service Manual, Page: 6 / 185

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KYMCO Super 8 50 Service Manual Download Page 6

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 

 

Summary of Contents for Super 8 50

Page 1: ...y 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 TA...

Page 2: ...Serial Number Frame Serial Number 1 ENGINE SERIAL NUMBER 1 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 TO...

Page 3: ...e 8 Valve clearance Intake 0 04 0 04 cold mm Exhaust 0 04 0 04 Idle speed rpm 2000rpm 2000rpm 2000rpm Lubricatio n System Lubrication type OIL PUMP Oil pump type Cycloid type Oil filter type Full flow...

Page 4: ...htening 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...

Page 5: ...e 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 connectin...

Page 6: ...ecified 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 conne...

Page 7: ...ed 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 ma...

Page 8: ...ake 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 e...

Page 9: ...ntact 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 she...

Page 10: ...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...

Page 11: ...cing methods and cautions included in this service manual Apply engine oil to the specified points Use designated engine oil for lubrication Apply grease for lubrication Transmission Gear Oil 90 Use s...

Page 12: ...m chain tensioner slipper bolt Oil bolt Clutch outer nut Clutch drive plate nut Starter motor mounting bolt Oil pump bolt Drive face nut Spark plug A C generator stator bolt Cam chain tensioner bolt 2...

Page 13: ...13000 crankshaft comp 12mm 14mm Clutch spring compressor E027 2301a driven pully assy 9 9 9 12 Cushion assemble disassemble tool F004 52400 cushion assy 13 4 Flywheel holder E017 31110 flywheel comp...

Page 14: ...onnecting rod piston pin hole Connecting rod big end Crankshaft R L side oil seal Starter reduction gear engaging part Countershaft gear engaging part Final gear engaging part Bearing movable part O r...

Page 15: ...ts not specified This will avoid abnormal noise and rise the durability of the motorcycle Rear Wheel Bearings Main Stand Pivot Speedometer Gear Front Wheel Bearings Brake Cam Anchor Pin Front Shock Ab...

Page 16: ...1 GENERAL INFORMATION 1 15 SUPER 8 50 CABLE HARNESS ROUTING Throttle Cable Front brake tube Fuel Pump Realy Horn Ignition Switch Low Beam realy Roll Sensor Speedometer High Beam realy...

Page 17: ...1 GENERAL INFORMATION 1 16 SUPER 8 50 Battery Cable Battery Cable Fuel Pump Fuel Level Indicator Fuel Tube Fuse...

Page 18: ...1 GENERAL INFORMATION 1 17 SUPER 8 50 Throttle Cable Fuel Tube Crankcase Breather Tube Ignition Coil Starter Relay Fuel Injector O Sensor ECU CPS...

Page 19: ...1 GENERAL INFORMATION 1 18 SUPER 8 50 WIRING DIAGRAM...

Page 20: ...CU Good spark Broken or shorted spark plug wire Faulty ignition switch Faulty ignition pulse generator Loose or disconnected spark plug wire 5 Test cylinder compression Low compression Valve stuck ope...

Page 21: ...eaner dirty not increase Restricted fuel flow Clogged muffler Engine speed increase Pinched fuel tank breather 4 Check ignition timing Incorrect Faulty ECU Faulty ignition pulse generator Correct 5 Te...

Page 22: ...ol orifice Valve train lubricated properly 11 Check for engine overheating Overheating Fan motor not working Excessive carbon build up in combustion chamber Use of poor quality fuel Not overheating Wr...

Page 23: ...ulator Normal 3 Inspect the fuel injector Abnormal Faulty injector Normal 4 Check for leaks in the intake pipe Leaking Loose insulator clamp Damage insulator No leak 5 Perform spark test Weak or inter...

Page 24: ...mshaft not installed properly Correct 5 Check valve spring Weak Faulty valve spring Not weak POOR HANDLING Possible cause 1 If steering is heavy Steering stem adjusting nut too tight Damaged steering...

Page 25: ...2 FRAME COVERS EXHAUST MUFFLER 2 0 NEW SUPER8 50 2 SCHEMATIC DRAWING 2...

Page 26: ...2 FRAME COVERS EXHAUST MUFFLER 2 1 NEW SUPER8 50...

Page 27: ...2 FRAME COVERS EXHAUST MUFFLER 2 2 NEW SUPER8 50...

Page 28: ...ndlebar rear cover Headlight wire connector Handlebar rear cover Speedometer cable and instrument light wire connectors etc Frame body cover Met in box rear grip rear turn signal lights floor board Fl...

Page 29: ...cover screw Disconnect the speedometer cable right and left handlebar switch couplers and the stop switch wire connectors Remove two screws inside the handlebar rear cover and remove the handlebar re...

Page 30: ...move the two bolt attaching the lefe and right rear step Remove the rear step Remove the two screws attaching the left side and right side skirt Remove the left side and right side skirt Rear Carrier...

Page 31: ...emove the center rear cover Remove the two bolts attaching the frame body cover Remove the two bolts attaching the rear fender Disconnect the taillight wire connector Remove the erar fender Remove the...

Page 32: ...oor board Remove the floor board F RONT FENDER AND UNDER COWL REMOVAL Remove the two on the under cowl Remove the under cowl Remove the L R side bolts attaching the front fender and front fender LEG S...

Page 33: ...e exhaust muffler Remove the exhaust muffler joint packing collar When installing first install the exhaust muffler packing collar and then install the exhaust muffler First install and tighten the ex...

Page 34: ...rea or fuel storage area SPECIFICATIONS ENGINE Throttle grip free play 2 6mm Spark plug gap 0 6 0 7mm Spark plug NGK CR7HSA Valve clearance IN 0 04mm EX 0 04mm Idle speed 2000rpm Engine oil capacity A...

Page 35: ...on timing 13 28 CHASSIS Front brake free play 10 20mm Rear brake free play 10 20mm TIRE PRESSURE 1 Rider 2 Riders Front 1 5kg cm2 2 0kg cm2 Rear 1 75kg cm2 2 25kg cm2 TIRE SIZE Front 120 70 14 Rear 12...

Page 36: ...R Gear oil Note 3 R New motorcycle 300km R R Valve clearance A A A A Air Cleaner Note 2 3 Replace at every2000km Spark plug Clean at every 3000km and replace if necessary Brake system I I I I I I I I...

Page 37: ...r adjustment of the throttle grip free play is made at the carburetor side Adjust by loosening the lock nut and turning the adjusting nut Minor adjustment is made with the adjusting nut at the throttl...

Page 38: ...the spark plug Check the spark plug for wear and fouling deposits Clean any fouling deposits with a spark plug cleaner or a wire brush Specified Spark Plug NGK CR7HSA Measure the spark plug gap Spark...

Page 39: ...ex mark on the crankcase to bring the round hole on the camshaft gear facing up to the top dead center on the compression stroke Inspect and adjust the valve clearance Valve Clearance IN 0 1mm EX 0 1m...

Page 40: ...m up the engine before compression test Remove the met in box and center cover 2 3 Remove the spark plug Insert a compression gauge Open the throttle valve fully and push the starter button to test th...

Page 41: ...with the recommended oil Oil Capacity At disassembly 0 21liter At change 0 18 liter Reinstall the oil check bolt and check for oil leaks Torque 0 8 1 2kgf m DRIVE BELT Remove the left crankcase cover...

Page 42: ...tch shoes for wear and replace if necessary 9 11 SUSPENSION FRONT Fully apply the front brake lever and check the action of the front shock absorbers by compressing them several times Check the entire...

Page 43: ...cm2 TIRE SIZE Front 120 70 14 Rear 120 80 14 Check the front axle nut for looseness Check the rear axle nut for looseness If the axle nuts are loose tighten them to the specified torques Torques Front...

Page 44: ...__________________________________________________________________ __________________________________________________________________________________ __________________________________________________...

Page 45: ...p must be replaced as a set when it reaches its service limit After the oil pump is installed check each part for oil leaks SPECIFICATIONS Item Standard mm Service Limit mm Inner rotor to outer rotor...

Page 46: ...filter screen spring and filter screen cap Torque 1 5kg m Fill with the specified SAE15W40 API SG engine oil to the proper level Oil Capacity At disassembly 0 90 liter At change 0 80 liter Check for...

Page 47: ...t and dowel pins Remove the starter idle gear and starter clutch Remove the two bolts and oil separator cover Remove the oil pump driven gear nut to remove the oil pump driven gear and drive chain Rem...

Page 48: ...ew DISASSEMBLY Remove the screw and disassemble the oil pump INSPECTION Measure the pump body to outer rotor clearance Service Limit 0 12mm Measure the inner rotor to outer rotor clearance Service Lim...

Page 49: ...sure that the pump shaft rotates freely without binding INSTALLATION Install the oil pump into the crankcase After the oil pump is installed tighten the two mounting bolts Install the pump driven gear...

Page 50: ...Starter Clutch Install the oil separator cover and tighten the bolts Install the starter idle gear and starter clutch Install the gasket and dowel pins Install the right crankcase cover and tighten th...

Page 51: ...ON 5 3 TROUBLESHOOTING 5 4 CHECK ENGINE LAMP CELP 5 5 HOW TO SHOW THE FAILURE CODE 5 6 FAILURE CODES CHART 5 7 ECU 5 11 FUEL PUMP 5 12 T MAP TPS 5 13 WTS 5 14 INJECTOR 5 14 O2 SENSOR 5 15 ROLL SENSOR...

Page 52: ...5 FUEL INJECTION SYSTEM Super8 50 5 1 SYSTEM DIAGRAM O2 CPS T MAP TPS WTS O2 Voltage INJECTOR ABV KEY OFF INDUCTIVE IGNITION COIL ECU FUEL PUMP KEY ON ROLL ETS...

Page 53: ...06 07 08 04 05 10 11 Parts Location 01 Inductive ignition coil 02 Fuel pump 03 ECU 04 Fuel injector 05 WTS sensor 06 T MAP sensor 07 ABV 08 TPS 09 Roll sensor Angle detect sensor 10 CPS 11 O2 O2 HT s...

Page 54: ...15 9 Water temperature sensor resistance 2 075 10 K 20 30 C Throttle position sensor voltage Idle 0 0 23 0 05V Throttle fully 90 3 27V over Fuel pump resistance 20 C 68 F F about 1100 E about 100 O2...

Page 55: ...oor performance drive ability and poor Faulty fuel pump operating system fuel economy Clogged fuel filter fuel pump Pinched or clogged fuel hose Clogged fuel injector Faulty fuel injector Faulty spark...

Page 56: ...get trouble There are three kinds of priority grade let user to know what kind of trouble was happened Priority grade 1 CELP blinks continuously This is the most emergent situation like engine over h...

Page 57: ...failure code and then show the other higher number one after four seconds All the failure codes would be shown repeatedly How To Reset Failure Code After repairing the trouble you should clear the fa...

Page 58: ...t malfunction 2 1 Check if the connector of crankshaft position sensor is loosen 2 Check if the Rotor is align with Crankshaft position sensor during the crankshaft running 3 P1120 Throttle position s...

Page 59: ...sensor or electric circuit malfunction 2 1 Check if the connector of Inlet air temperature sensor loosen 2 Check if the resistance of sensor is normal 8 P0410 Idle air valve or electric circuit malfun...

Page 60: ...han top speed 2 Check if the belt of CVT is broken 14 P1560 Sensor don t receive power source from ECU 2 1 Check if ECU output DC5V to sensor 2 Check if the power source of all sensor is DC5V 3 Replac...

Page 61: ...n 22 P1110 Roll sensor or electric circuit malfunction 2 1 Check if the sensor installation direction is correct 2 Check if voltage of sensor is fit in specification 3 Check if ECU pin is broken 23 P0...

Page 62: ...8 50 5 11 ECU There are 36 pins attaching the ECU Part number 3920A LHB6 900 Voltage inspection Connect the meter probe to the F4 R W wire and the meter probe to the H4 G B wire to measure the voltage...

Page 63: ...nnect the meter probe to the red black wire and the meter probe to the green wire to measure the voltage from the ECU input to fuel pump unit Standard 8 16 V Battery volt To measure the resistance of...

Page 64: ...ition If data is incorrect and the T map sensor is problem Standard 101 3 3 kpa on sea altitude The ambient pressure drop is about 12Kpa according to the altitude raises TPS Throttle Position Sensor E...

Page 65: ...ensor Connect the meter probe to the V G wire and the meter probe to the G L wire to measure the voltage Standard 5 0 25 V Measure the resistance of the WTS Standard 20 C 68 F 2 075 10 k INJECTOR Meas...

Page 66: ...sor heater 2 white wire pin Standard 20 C 68 F 6 7 9 5 Connect the PDA or KYMCO Fi diagnostic tool Enter the Data Analyze Check Page 05 Turn the ignition switch to the ON position Starting engine till...

Page 67: ...place the vehicle back to normal position you have to key off and key on the switch again then it can be restarted Standard Normal 0 4 1 4V Fall down 65 3 7 4 4 V TP SCREW Don t adjust the TP screws...

Page 68: ...adjust the air bypass adjustment screw it may cause to unstable problem TPI ABV Initialization After replacing throttle body or engine overhauled it cause to the efficiency of air intake be changed s...

Page 69: ...000 100 rpm MAPSample kPa 52 68 kpa Injection duration ms 1 9 3 ms Ign Advance 4 17 BTDC Ign Dwell duration ms Air Temp C environ temp 2 C Engine Temp C 95 C O2 sensor voltage V 0 1 V O2 sensor heater...

Page 70: ...stic Tool Operation Instructions Part No 3620A LEB2 E00 1 Model No 2 Down Button 3 DTCindicator Failure codes 4 EnterorExit 5 Power indicator 6 UP Button 7 Adjust TPIandABVreset function 8 DATA Analyz...

Page 71: ...INSPECTION Connect Fi diagnostic tool with the connector of harness wirelocatedbeside theBattery Press the Enter button Check thesoftwareversion Press the Enter button and then turn to the first page...

Page 72: ...21 Super 8 50 Press the Enter button to checkthe DTCnumber Press the Enter button Press the Enter button DisplaytheDTC number of the DTC List Refer to DTCsummarylist Press the Enter button and then t...

Page 73: ...5 FUEL INJECTION SYSTEM 5 22 Super 8 50 Press the UP button Press the Enter button and then turn to thee previous page Press the UP button Press the Enter button and then turn to the first page...

Page 74: ...5 FUEL INJECTION SYSTEM 5 23 Super 8 50 DTC CLEAR PROCEDURE Choose Load DTC Press the Down button Press the Enter button TheDTCindicatoris lightingat thattime Clearing DTCuntil theDTC indicatoris off...

Page 75: ...dardspecification Press the Down button to enterpage02 The figure includes TPS position TPI idle adapted voltage and TPI WOT adapted Throttle gripfullyopened Refer tostandardspecification Press the Do...

Page 76: ...ss the Down button toenterpage05 The figure includes O2 sensor voltage O2 heater workingcondition and O2 correction Refer tostandardspecification Press the Down button to enterpage06 Thefigureincludes...

Page 77: ...TPI ABV reset after replacing a new ECU or clean Throttle Body To make ECU set up and set up initially Choose Adjust Press the Enter button toTPI ABVReset Press the Enter button Pleaseturntheignitions...

Page 78: ...6 ENGINE REMOVAL INSTALLATION 6 0 SUPER 8 50 6 6...

Page 79: ...required to support and maneuver the engine Be careful not to damage the motorcycle body cables and wires during engine removal Use shop towels to protect the motorcycle body during engine removal Par...

Page 80: ...starter wire connector Disconnect the starter motor cable from the starter relay Remove the spark plug cap and disconnect the ignition coil wire from the set plate Disconnect the fuel tube from the th...

Page 81: ...d pull out the engine with the engine hanger bracket backward ENGINE HANGER BRACKET REMOVAL Remove the ignition coil from the engine hanger Remove the engine hanger bracket bolt and nut Remove the eng...

Page 82: ...stall the engine and tighten the engine mounting bolt Torque 7 0kg m Tighten the rear shock absorber upper mount bolt Torque 4 0kg m Install the removed parts in the reverse order of removal After ins...

Page 83: ...7 CYLINDER HEAD VALVES 7 0 Super 8 50 7 7...

Page 84: ...assembling install them in the reverse order of removal SPECIFICATIONS Item Standard mm Service Limit mm IN 0 04 EX 0 04 Cylinder head compression pressure 14kg cm Cylinder head warpage 0 05 IN 25 70...

Page 85: ...te smoke from exhaust muffler Compression too low Worn valve stem or valve guide Damaged valve stem seal Compression too low Incorrect valve clearance adjustment Abnormal noise Burned or bend valves I...

Page 86: ...move the cam chain tensioner cap screw and the O ring Turn the cam chain tensioner screw clockwise to tighten it Turn the flywheel counterclockwise so that the T mark on the flywheel aligns with the i...

Page 87: ...Remove the camshaft gear from the cam chain and remove the camshaft CAMSHAFT INSPECTION Check each cam lobe for wear or damage Measure the cam lobe height Service Limits IN 26 038mm replace if below...

Page 88: ...AFT HOLDER INSPECTION Inspect the camshaft holder valve rocker arms and rocker arm shafts for wear or damage Measure the I D of each valve rocker arm Service Limits IN 10 10mm replace if over EX 10 10...

Page 89: ...ine cover bolts and screws Separate the engine cover joint claws Remove the cylinder head Remove the dowel pins and cylinder head gasket Remove the cam chain guide Remove all gasket material from the...

Page 90: ...heck the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and feeler gauge Service Limit 0 05mm repair or replace if over VALVE SPRING FREE LENGTH Me...

Page 91: ...replace if over EX 0 10mm replace if over CYLINDER HEAD ASSEMBLY Install the valve spring seats and valve stem seals Lubricate each valve stem with engine oil and insert the valves into the valve gui...

Page 92: ...nder head CAMSHAFT HOLDER ASSEMBLY Install the exhaust valve rocker arm to the EX mark side of the camshaft holder Install the intake valve rocker arm and the rocker arm shafts Gasket Valve Rocker Arm...

Page 93: ...shaft onto the cylinder head Install the cam chain over the camshaft gear Install the dowel pins Install the camshaft holder washers and nuts on the cylinder head Tighten the four cylinder head nuts a...

Page 94: ...he cam chain tensioner cap screw Install a new cylinder head cover O ring and install the cylinder head cover Install and tighten the cylinder head cover bolts Cylinder Head Cover O ring Be sure to in...

Page 95: ...8 CYLINDER PISTON 8 0 Super 8 50 8 8 Do not bend...

Page 96: ...02 13 008 13 04 Piston pin O D 12 994 13 000 12 96 Piston to piston pin clearance 0 002 0 014 Connecting rod small end I D bore 13 016 13 034 13 06 TROUBLESHOOTING When hard starting or poor performan...

Page 97: ...der Remove the cylinder gasket and dowel pins Clean any gasket material from the cylinder surface PISTON REMOVAL Remove the piston pin clip Press the piston pin out of the piston and remove the piston...

Page 98: ...ove clearance Service Limits Top 0 09mm replace if over 2nd 0 09mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom Measure the piston ring end gap Service...

Page 99: ...the piston pin in both X and Y directions Service Limit 39 10mm repair or replace if over Measure the cylinder to piston clearance Service Limit 0 1mm repair or replace if over The true roundness is t...

Page 100: ...ice Limit 13 06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston Apply engine oil to each piston ring Second Side Rail Top Side Rail Oil Ring Be careful not to damag...

Page 101: ...and piston rings with clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings Gasket Cylinder Be careful not to drop foreign matters into the crankcase Piston Pin...

Page 102: ...8 50 Loosely install the cylinder base bolts Install the cam chain guide Install the cylinder head Tighten the cylinder base bolts Cylinder Base Bolt Cam Chain Guide Insert the tab on the cam chain gu...

Page 103: ...9 DRIVE AND DRIVEN PULLEYS 9 0 Super 8 50 9 9...

Page 104: ...Driven face spring free length 97 Driven face O D 33 965 33 485 33 94 Movable driven face I D 34 0 34 025 34 06 Weight roller O D 15 920 16 080 15 4 TORQUE VALUES Drive face nut 5 5 6 5kgf m Clutch ou...

Page 105: ...eal rubber and dowel pins INSTALLATION Install the dowel pins and gasket Install the left crankcase cover and tighten the left crankcase cover bolts Install the cable clamp to the specified location a...

Page 106: ...rsal holder and remove the clutch outer nut Remove the clutch driven pulley and drive belt INSPECTION Check the drive belt for cracks separation or abnormal or excessive wear Measure the drive belt wi...

Page 107: ...MBLY Remove the ramp plate Remove the weight rollers INSPECTION Check each weight roller for wear or damage Measure each weight roller O D Service Limit 15 4mm replace if below Drive Pulley Collar Ram...

Page 108: ...e Limit 24 06mm replace if over Check the drive pulley collar for wear or damage Measure the O D of the drive pulley collar sliding surface Service Limit 19 97mm replace if below ASSEMBLY Install the...

Page 109: ...into the movable drive face INSTALLATION Install the movable drive face onto the crankshaft Lay the drive belt on the driven pulley Set the drive belt on the drive pulley collar Drive Pulley Collar D...

Page 110: ...Holder INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit 125 5mm replace if over Check the clutch shoes for wear or damage Drive Pulley Face Starting Ra...

Page 111: ...assembly with the clutch spring compressor Clutch Spring Compressor Set the clutch spring compressor in a vise and remove the clutch drive plate nut Loosen the clutch spring compressor and disassembl...

Page 112: ...he driven face Remove the oil seal from the movable driven face INSPECTION Measure the driven face spring free length Service Limit 97mm replace if below Check the driven face for wear or damage Measu...

Page 113: ...en pulley face Remove the drive the outer bearing out of the driven face Apply grease to the outer bearing Drive a new outer bearing into the driven face with the sealed end facing up Apply grease to...

Page 114: ...d clutch springs onto the drive plate Install the retainer plate and secure with the circlips CLUTCH DRIVEN PULLEY ASSEMBLY Clean the driven pulley faces and remove any grease from them Install the oi...

Page 115: ...g compressor and install the drive plate nut Set the clutch spring compressor in a vise and tighten the drive plate nut to the specified torque Torque 5 5kg m Clutch Spring Compressor INSTALLATION Ins...

Page 116: ...Install the clutch outer Hold the clutch outer with the universal holder Install and tighten the clutch outer nut Torque 5 5kg m Flywheel Holder Install the drive belt Install the left crankcase cover...

Page 117: ...10 FINAL REDUCTION 10 0 Super 8 50 10...

Page 118: ...SHOOTING Engine starts but motorcycle won t move Damaged transmission Seized or burnt transmission Faulty drive belt Faulty clutch Abnormal noise Worn seized or chipped gears Worn bearing Oil leaks Oi...

Page 119: ...mission gear oil into a clean container Remove the transmission case cover attaching bolts Remove the transmission case cover Remove the gasket and dowel pins Remove the final gear and countershaft FI...

Page 120: ...ARING REPLACEMENT TRANSMISSION CASE COVER Remove the transmission case cover bearings using a bearing puller Remove the final shaft oil seal Bearing Puller Drive new bearings into the transmission cas...

Page 121: ...t crankcase bearings using a bearing puller Bearing Puller Drive new bearings into the left crankcase Install a new drive shaft oil seal FINAL REDUCTION ASSEMBLY Install the drive shaft into the left...

Page 122: ...fied oil 3 7 Specified Gear Oil SAE90 Oil Capacity At disassembly 0 2 liter At change 0 18 liter Install and tighten the oil check bolt Torque 0 8 1 2kgf m Start the engine and check for oil leaks Che...

Page 123: ...11 CRANKCASE CRANKSHAFT 11 0 Super 8 50 11 11...

Page 124: ...r air cleaner Section 5 Rear wheel rear shock absorber Section 13 Starter motor Section 16 Oil pump Section 4 SPECIFICATIONS Item Standard mm Service Limit mm Connecting rod big end side clearance 0 1...

Page 125: ...e left and right crankcase halves Remove the gasket and dowel pins Remove the crankshaft and cam chain from the left crankcase Clean off all gasket material from the crankcase mating surfaces Dowel Pi...

Page 126: ...everse of removal CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 55mm replace if over Measure the connecting rod big end radial clearance at two points at righ...

Page 127: ...ey fit loosely in the crankshaft replace the crankshaft as a set CRANKCASE ASSEMBLY Install the cam chain into the left crankcase Install the crankshaft into the left crankcase Install the dowel pins...

Page 128: ...11 CRANKCASE CRANKSHAFT 11 5 Super 8 50 Tighten the two crankcase attaching bolts Torque 0 8 1 2kg m Crankcase Bolts...

Page 129: ...12 FRONT WHEEL FRONT BRAKE FRONT SUSPENSION 12 0 Super 8 50 12 12...

Page 130: ...SPECIFICATIONS Item Standard mm Service Limit mm Axle shaft runout 0 2 Front wheel rim runout Radial 2 0 Axial 2 0 Front shock absorber spring free length 230 226 5 TORQUE VALUES Handlebar bolt 4 5 5...

Page 131: ...earing play Broken steering balls Bent spoke plate Insufficient tire pressure Faulty tire Steers to one side or does not track straight Improperly tightened axle nut Uneven front shock absorbers Soft...

Page 132: ...screws and throttle holder Disconnect the throttle cable from the throttle pipe and then remove the throttle pipe from the handlebar Remove the handlebar lock nut and bolt to remove the handlebar INST...

Page 133: ...front wheel off the ground Remove the speedometer cable set screw and disconnect the speedometer cable Remove the front axle nut and pull out the axle Remove the front wheel Remove the and speedometer...

Page 134: ...s Radial 2 0mm replace if over Axial 2 0mm replace if over Turn the wheel bearings and replace the bearings if they are noisy or have excessive play DISASSEMBLY Remove the dust seal Remove the front w...

Page 135: ...with grease Drive in the left bearing Install the distance collar Drive in the right bearing Apply grease to a new dust seal lip and install the dust seal Install the side collar Drive in the bearing...

Page 136: ...sure to bleed air from the brake system When operating the brake lever the brake reservoir cap must be tightened securely to avoid spill of brake fluid When servicing the brake system use shop towels...

Page 137: ...d and remove the brake pads Install the brake pads in the reverse order of removal Brake Disk Measure the brake disk thickness Service Limit 3 0mm Measure the brake disk runout Service Limit 0 3mm The...

Page 138: ...r main piston and spring from the brake master cylinder Clean the inside of the master cylinder and brake reservoir with brake fluid When servicing the brake system use shop towels to cover rubber and...

Page 139: ...t the lst and 2nd rubber cups for wear Assembly Before assembly apply brake fluid to all removed parts Install the spring together with the 1st rubber cup Install the main piston spring and snap ring...

Page 140: ...eeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratch or wear and...

Page 141: ...the brake fluid pipe with the attaching bolt and two sealing washers Install the handlebar covers 12 3 Fill the brake reservoir with recommended brake fluid to the upper limit and bleed air according...

Page 142: ...4 5mm Assembly Clean all removed parts Apply silicon grease to the piston and oil seal Lubricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved s...

Page 143: ...tall the brake caliper and tighten the two bolts Torque 2 9 3 5kg m Connect the brake fluid pipe to the brake caliper and tighten the fluid pipe bolt Torque 2 5 3 5kg m Fill the brake reservoir with r...

Page 144: ...the dust boot Remove the circlip Set the front shock absorber in a vise Remove the damper rod hex bolt and copper washer Pull out the front shock absorber tube Set the front shock absorber tube in a v...

Page 145: ...bsorber spring free length Service Limits Right 226 5mm Left 226 5mm ASSEMBLY Install the damper spring onto the damper rod and then install them into the front shock Front Shock Absorber Shock Absorb...

Page 146: ...3 0kgf m Add engine oil into the front shock absorber Specified Oil SS 8 Oil Capacity 97 1cc Install the circlip Install the dust boot INSTALLATION Install the front shock absorbers onto the steering...

Page 147: ...ing stem Inspect the ball races and cone races for wear or damage and replace if necessary BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race using a chisel Drive a new bottom cone race into pla...

Page 148: ...tall it Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely Install the steering stem lock nut and tighten it while ho...

Page 149: ...__________________________________________________________ ________________________________________________________________________________ ____________________________________________________________...

Page 150: ...13 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER 1 Super 8 50...

Page 151: ...Remove the suspension upper mount bolt Remove the suspension lower mount bolt Remove the rear shock absorber INSTALLATION Install the upper and lower mount bolts Install the frame body cover Torque Up...

Page 152: ...EMBLY Remove the rear brake adjusting nut and disconnect the rear brake cable Remove the rear brake shoes Remove the brake arm bolt to remove the brake arm Remove the brake cam REAR BRAKE ASSEMBLY App...

Page 153: ...tall the brake arm return spring Install the brake arm pin Connect the brake cable and install the adjusting nut Install the rear wheel 13 2 Adjust the rear brake lever free play 3 8 Align the wide gr...

Page 154: ...14 BATTERY CHARGING SYSTEM A C GENERATOR 14 0 Super 8 50 14 14 Regulator Rectifier A C Generator P R B L Battery Fuse G Y 5P B Y P R1 Fuse Regulator Rectifier A C Generator Battery CDI...

Page 155: ...ty is insufficient Recharging a new battery will prolong its service life Inspect the charging system according to the sequence specified in the Troubleshooting Do not disconnect and soon reconnect th...

Page 156: ...r coil bolt 0 45 0 6kgf m Stator bolt 0 8 1 2kgf m Flywheel nut 3 5 4 5kgf m Cooling fan bolt 0 8 1 2kgf m SPECIAL TOOLS Universal holder Flywheel puller TESTING INSTRUMENTS Kowa electric tester Sanwa...

Page 157: ...ard 0 4A Quick 4A Charging time Standard 5 10 hours Quick 30 minutes After charging Open circuit voltage 12 8V min Note The battery temperature should not exceed 45 during charging When disconnecting...

Page 158: ...en the battery is fully charged Warm up the engine for inspection Connect the electric tester across the battery terminals Disconnect the fuse and connect an ammeter between the fuse terminals Attach...

Page 159: ...A C generator stator nought resistance REGULATOR RECTIFIER REMOVAL Remove the regulator rectifier lock nut and disconnect the regulator rectifier wire coupler Measure the resistances between the regu...

Page 160: ...and engine ground with an electric tester Standard 0 1 1 0 at 20 Replace the A C generator charging coil if the reading is not within the specifications A C GENERATOR REMOVAL Remove the right side cov...

Page 161: ...g bolts Hold the flywheel with an universal holder Remove the flywheel nut Universal Holder Remove the A C generator flywheel using the flywheel puller Remove the woodruff key Flywheel Puller Remove t...

Page 162: ...and A C generator stator A C GNERATOR INSTALLATION Install the A C generator stator and pulser coil onto the right crankcase Tighten the stator and pulser coil bolts Torques Pulser Coil 0 45 0 6kgf m...

Page 163: ...ywheel onto the crankshaft with the flywheel hole aligned with the crankshaft woodruff key Hold the flywheel with the universal holder and tighten the flywheel nut Torque 3 5 4 5kgf m Universal Holder...

Page 164: ...14 BATTERY CHARGING SYSTEM A C GENERATOR 14 10 Super 8 50 Install the fan cover Install the right side cover 2 4 Fan Cover...

Page 165: ...15 IGNITION SYSTEM 0 Super 8 50 15 15 Starter Relay A C Generator Spark Plug ECU Ignition Coil Main Switch Roll sensor...

Page 166: ...ctory The ignition control module or ECU maybe damaged if dropped or the connector is disconnected when the key is ON the excessive voltage may damage the ignition control module or ECU Always turn of...

Page 167: ...ition Sensor 96 144 Angle Detect Sensor 0 4V 1 44V normal 3 7V 4 4V fall down TROUBLESHOOTING No peak voltage Short circuit in engine stop switch or ignition switch wire Faulty engine stop switch or i...

Page 168: ...on coil bolt and ignition coil INSPECTION CONTINUITY TEST Measure the resistance between the ignition coil primary coil terminals Resistance 0 1 1 0 Measure the secondary coil resistances with and wit...

Page 169: ...160 Refer to page 14 6 for the A C generator removal IGNITION TIMING INSPECTION Remove the timing hole cap Warm up the engine and check the ignition timing with a timing light When the engine is runni...

Page 170: ...l as shown at the ignition switch ON Measure the voltage as below Terminal Standard Violet Red Violet Green 5 V ECU voltage Black White Violet Green 0 4 1 44 V less Incline the tilt switch 65 10 degre...

Page 171: ...0 REMOVAL INSTALLATION Disconnect the connector and remove two screws then remove tilt switch Installation is in the reverse order of removal Tighten the mounting screws securely Install the tilt swit...

Page 172: ...16 STARTING SYSTEM 16 0 Super 8 50 16 16 Starter Relay Starter Motor...

Page 173: ...wheel Holder TROUBLESHOOTING Starter motor won t turn Lack of power Fuse burned out Weak battery Weak battery Loose wire or connection Faulty ignition switch Foreign matter stuck in starter motor Faul...

Page 174: ...necessary Clean the commutator if there is metal powder between the segments Check for continuity between pairs of the commutator segments and there should be continuity Also make a continuity check...

Page 175: ...tinuity between the wire terminal and each brush Replace if necessary Measure the length of the brushes Service Limit 8 5mm replace if below Check for continuity between the brushes If there is contin...

Page 176: ...lick sound Inspect the starter relay voltage Inspect the starter relay ground circuit Inspect the starter relay operation STARTER RELAY VOLTAGE INSPECTION Place the motorcycle on its main stand Measur...

Page 177: ...ter motor cable Connect a fully charged battery across the starter relay yellow red and green yellow wire terminals Check for continuity between the starter relay large terminals The relay is normal i...

Page 178: ...rive gear for wear or damage and replace if necessary Measure the starter drive gear I D Service Limit 32 06mm replace if over Inspect the needle bearing for wear or damage and replace if necessary CL...

Page 179: ...the threads of the clutch cover bolts and tighten them Torque 1 2kg m Apply engine oil to the needle bearing and starter drive gear and then install them to the clutch body INSTALLATION Install the s...

Page 180: ...er switch is ON correctly Burned bulb Disconnected wire or connector Faulty switch Broken wire Broken wire Faulty float Fuse burned out Faulty fuel unit Weak battery Faulty instrument Poorly connected...

Page 181: ...L W 566 153 Y W L W 599 599 FUEL GAUGE INSPECTION Connect the fuel unit wire connector and turn the ignition switch ON Check the fuel gauge needle for correct indication by moving the fuel unit float...

Page 182: ...between wire terminals If there is any abnormality found check each switch HEADLIGHT SWITCH Color Black Brown Blue White Brown White STARTER SWITCH Color Yellow Red Green FREE PUSH DIMMER SWITCH Colo...

Page 183: ...ect the ignition switch wire coupler Check for continuity between the wire terminals Color Black Red Black Blue Green OFF ON LOCK IGNITION SWITCH REPLACEMENT Remove the front covers 2 2 Disconnect the...

Page 184: ...normal if there is continuity HORN INSPECTION Remove the front covers 2 2 Disconnect the horn wire coupler The horn is normal if it sounds when a 12V battery is connected across the horn wire terminal...

Page 185: ...cover The installation sequence is the reverse of removal BULB REPLACEMENT Remove the headlight bulb Coupler 2 2 Remove the headlight replace with new bulbs The installation sequence is the reverse o...

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