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KYMCO SUPER8 50, Service Manual, Page: 97 / 188

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KYMCO SUPER8 50 Service Manual Download Page 97

9

. FINAL REDUCTION

 

9-2

SUPER8 50 2T

SERVICE INFORMATION

Specified Oil: SAE90#
At disassembly: 0.12 liter
At change:

0.1 liter

SPECIAL TOOLS

Bearing remover set, 12mm
Bearing remover set, 15mm
Crankcase assembly collar
Crankcase assembly shaft
Bearing outer driver, 37x40mm
Bearing outer driver, 32x35mm
Bearing driver pilot, 17mm
Bearing driver pilot, 15mm
Bearing driver pilot, 12mm
Bearing outer driver handle A

TROUBLESHOOTING

Engine starts but motorcycle won‘t move

•

Damaged transmission

•

Seized or burnt transmission

Abnormal noise

•

Worn, seized or chipped gears

•

Worn bearing

Oil leaks

•

Oil level too high

•

Worn or damaged oil seal

Summary of Contents for SUPER8 50

Page 1: ...ER 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...

Page 2: ...controlled Port Open timing Exhaust Close Open Scaveng e Close Idle speed rpm 1850 100 Lubrication type Separate type Oil pump type Plunger type Oil filter type Full flow filtration Lubrication oil c...

Page 3: ...________________________________________________________________________________ ________________________________________________________________________________ GENERAL INFORMATION __________________...

Page 4: ...2 GENERAL INFORMATION 2 1 SUPER8 50 2T ENGINE SERIAL NUMBER IDENTIFICATION Location of Engine Serial Number...

Page 5: ...ghtening 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 6: ...he 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 connecti...

Page 7: ...pecified 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 conn...

Page 8: ...ged 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 m...

Page 9: ...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...

Page 10: ...ontact 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 sh...

Page 11: ...re 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 instructio...

Page 12: ...ng symbols represent the servicing 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...

Page 13: ...end I D 17 005 17 017 17 03 Cylinder bore 39 0 39 025 39 05 Drive belt width 18 17 Drive pulley collar O D 20 01 20 025 Movable drive face ID 20 035 20 085 19 97 Weight roller O D 13 0 12 4 Clutch out...

Page 14: ...ckness Front rear 5 7 4 0 2 0 2 0 Brake disk runout Front rear 0 30 Rear shock absorber spring free length 235 7 218 7 ELECTRICAL EQUIPMENT SUPER8 50 2T Capacity 12V6AH Voltage 13 0 13 2V Charging Sta...

Page 15: ...bolt lower mount bolt hex bolt Front damper nut Front pivot arm bolt Rear shock absorber upper mount bolt lower mount bolt lower joint nut 10 25 4 25 4 12 16 8 8 10 8 8 4 5 5 0 7 0 8 0 0 5 1 3 5 0 7...

Page 16: ...g installation Bearing remover Driven pulley outer bearing installation Clutch spring compressor Driven pulley disassembly assembly Crankcase assembly collar Driven shaft crankshaft crankcase assembly...

Page 17: ...lation Bearing driver pilot 17mm Drive shaft bearing installation Snap ring pliers close Circlip removal installation Bearing outer driver 42x47mm Crankshaft bearing installation Pilot 20mm Crankshaft...

Page 18: ...able parts Grease 6 Starter pinion movable parts Grease FRAME Apply clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and rise the durability of the m...

Page 19: ...2 GENERAL INFORMATION 2 16 SUPER8 50 2T PEOPLE S 50 WIRING DIAGRAM...

Page 20: ...AL INFORMATION SUPER8 50 2T 2 17 CABLE HARNESS ROUTING Front Brake Reservoir Rear Brake Cable Throttle Cable Front Stop Brake Rear Stop Brake Front Brake Fluid Tube Speedometer Cable Horn Regulator Re...

Page 21: ...GENERAL INFORMATION 2 18 SUPER8 50 2T Wire Harness Rear Brake Cable Throttle Cable Front Brake Fluid Tube Speedometer Cable Ignition Switch Starter Switch Horn Switch Turn Signal Switch Dimmer Switch...

Page 22: ...ATION SUPER8 50 2T 2 19 Reed Valve Motor Connect wire Oil Meter Oil Tube Spark Plug Air Cleaner Ignition Coil Air Injection Control Valve Fuel Unit Fuel Tube Oil Filter Fuel Tank Oil Tank Fuel Cap Muf...

Page 23: ...2 GENERAL INFORMATION 2 20 SUPER8 50 2T Wire Harness Battery Cable A C G Connect wire Starter Relay Oil Control Cable Spark Plug Cap Auto Bystarter wire Battery Cable Fuel Tank Cap Oil Tube...

Page 24: ...pipe eIncorrect ignition timing cFlooded carburetor dThrottle valve excessively open cFaulty auto bystarter Check if fuel reaches carburetor by loosening drain screw Remove spark plug and install it i...

Page 25: ...ure too rich turn screw out dMixture too lean turn screw in Check if fuel reaches carburetor by loosening drain screw Inspection Adjustment Symptom Probable Cause Fuel reaches carburetor Good spark Re...

Page 26: ...ystarter cFaulty auto bystarter Inspection Adjustment Symptom Probable Cause No air leak Not clogged Clogged Air leaks Clogged Not Clogged Check carburetor gasket for air leaks Connect auto bystarter...

Page 27: ...build up in combustion chamber dPoor quality fuel eClutch slipping fMixture too lean Inspection Adjustment Symptom Probable Cause Engine speed increases Engine overheats Correct timing Engine does no...

Page 28: ...wire dFaulty auto bystarter Inspection Adjustment Symptom Probable Cause Clogged Not clogged Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Check...

Page 29: ...ter Inspection Adjustment Symptom Probable Cause Clogged Not clogged Check ignition timing Connect auto bystarter wire to battery Wait for 5 minutes then connect a hose to fuel enriching circuit and t...

Page 30: ...led drive belt dWorn drive belt eWeak driven face spring fWorn or seized driven pulley bearings STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Front and rear tire pressures are normal cSteering stem nut t...

Page 31: ...ke cam fWorn brake drum cWorn brake linings dForeign matter on brake linings eRough brake drum contacting area cSluggish or elongated brake cables dBrake shoes improperly contact brake drum eWater and...

Page 32: ...y connected wire cFaulty float dBroken or shorted wire in meter cDamaged oil tank dForeign matters in oil tank Inspection Adjustment Symptom Inspection Adjustment Probable Cause Symptom Probable Cause...

Page 33: ...ion Adjustment Symptom Symptom Signals operate properly Signals operate properly Signals dim remain on or don t operate Signals dim remain on or don t operate Pointer does not move Pointer does not mo...

Page 34: ...stuck closed Inspection Adjustment Inspection Adjustment Inspection Adjustment Symptom Symptom Symptom Signals operate properly Signals operate properly Signals dim remain on or don t operate Signals...

Page 35: ...___________________________ __________________________________________________________________________ __________________________________________________________________________ INSPECTION ADJUSTMENT...

Page 36: ...and vertical play Steering handlebar Operating performance Right left turning angle Suspension Damage Check for front fork pivot installation Check steering stem Front fork Check front fork pivot for...

Page 37: ...xial 2 0mm Radial 2 0mm Rear Axial 2 0mm Radial 2 0mm Check front wheel bear ing for excessive play and abnormal noise Check front wheel bear ing for excessive play and abnormal noise Frame Spring Dam...

Page 38: ...arburetor throttle valve and auto bystarter Check fuel filter for clogging Fuel level Fuel System Fuel tube replacement Every 4 years Operation Lights Winker Winking action dirt and damage Buzzer Stee...

Page 39: ...Recommend brake fluid DOT4 BRAKE LEVER Measure the front and rear brake lever free plays Free Play Rear 10 20mm If the free plays do not fall within the limits turn the right and left adjusting nuts...

Page 40: ...r or damage BRAKE DISK LINING Brake Disk Surface and Brake Pad Wear Check the brake disk surface for scratch Check if the brake pad wear is within the specified service limit Brake Disk Run out Inspec...

Page 41: ...4 52P Axle Nut Axle Shaft Looseness Check the front and rear axle nuts for looseness If the axle nuts are loose tighten them to the specified torques Torques Front 5 0 7 0kg m Rear 11 0 13 0kg m Wheel...

Page 42: ...s Check the entire shock absorber assembly for looseness or damage POWER DRIVE SYSTEM TRANSMISSION CASE Check the rear wheel transmission case surrounding area for oil leaks Stop the engine and remove...

Page 43: ...e the A C generator fan cover 7 3 Remove the three bolts attaching the fan cover and then remove the fan cover Warm up the engine and check the ignition timing with a timing light When the engine is r...

Page 44: ...fied range by turning the throttle stop screw and air screw Idle Speed 1850 100rpm Air Cleaner Remove the air cleaner cover by removing the five bolts cleaner cover screws Remove the air cleaner eleme...

Page 45: ...ression is low check for the following Leaking cylinder head gasket Worn piston cylinder If the compression is high it indicates that carbon deposits have accumulated on the combustion chamber and the...

Page 46: ...ing the control cable lock nut and turning the adjusting nut After adjustment tighten the lock nut If the oil pump is not synchronized properly the following will occur Excessive white smoke or hard s...

Page 47: ...ot fall within the specified range adjust by loosening the lock nut and turning the adjusting nut OTHERS LIGHTS Headlight Front upper cover remove 12 5 Adjust the headlight beam by loosening the headl...

Page 48: ...__________________________________ ________________________________________________________________________________ ________________________________________________________________________________ LUB...

Page 49: ...4 LUBRICATION SYSTEM 4 1 SUPER8 50 2T LUBRICATION SYSTEM...

Page 50: ...before connecting it SPECIFICATIONS Recommended Motor Oil 2 stroke Motor Oil Oil Capacity 1 1 liter Light comes on 0 5 liter TROUBLESHOOTING Excessive white smoke or carbon deposits on spark plug Oil...

Page 51: ...eakened O ring Damage to crankcase mating surface Damage to pump body Control lever operation Oil leaks through oil seals Worn or damaged pump pinion Do not allow foreign matters to enter the crankcas...

Page 52: ...let line and oil outlet line properly Connect the oil pump control cable Bleed air from the oil pump Lubricate the O ring with grease or engine oil before installation Make sure that the oil pump is i...

Page 53: ...f the tube by filling it with oil 2 Start the engine and allow it to idle with the oil control lever in the fully open position Visually check the oil flow 3 If there is no oil flowing out within 1 mi...

Page 54: ...ve the two bolts attaching the oil tank Disconnect the oil inlet line Drain the oil inside the oil tank into a clean container Remove the oil tank The installation sequence is the reverse of removal C...

Page 55: ...____________________________________________________________________________ ________________________________________________________________________________ __________________________________________...

Page 56: ...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 Parts requiring engine removal for s...

Page 57: ...e carburetor cap Disconnect the auto bystarter A C generator and starter motor wire connectors Disconnect the oil pump control cable from the pump body Disconnect the oil inlet line from the oil pump...

Page 58: ...left engine mounting nuts Take out the right and left engine mounting bolts Lift the frame upward to separate it from the engine and be careful not to damage the rear fender ENGINE HANGER BRACKET REM...

Page 59: ...ON Install the engine in the reverse order of removal Torque Values Engine mounting bolt 4 5 5 5kg m Rear shock absorber lower mount bolt 2 4 3 0kg m Perform the following inspections and adjustments...

Page 60: ..._____________________________________________________________________ ________________________________________________________________________________ _________________________________________________...

Page 61: ...6 CYLINDER HEAD CYLINDER PISTON 6 1 SUPER8 50 2T Torque 1 5 1 7kg m Torque 1 1 1 7kg m cold...

Page 62: ...90 Cylinder to piston clearance 0 10 Piston pin hole I D 12 002 12 008 12 03 Piston pin O D 11 994 12 0 11 98 Piston to piston pin clearance Piston ring end gap top second 0 10 0 25 0 40 Connecting ro...

Page 63: ...the two exhaust muffler lock bolts Remove the bolt attaching the engine hood to remove the engine hood The installation sequence is the reverse of removal Remove the spark plug Remove the cylinder he...

Page 64: ...r warpage with a straight edge and feeler gauge Service Limit 0 10mm replace if over CYLINDER HEAD INSTALLATION Install the cylinder head on the cylinder properly Install a new cylinder head gasket on...

Page 65: ...in 2 or 3 times Torque 1 5 1 7kg m Install the spark plug Torque 1 1 1 7kg m Engine Hood Installation Install the engine hood 6 3 Install the spark plug cap 6 3 Perform the following inspections afte...

Page 66: ...er gasket PISTON REMOVAL Remove the piston pin clip to remove the piston pin and piston Spread each piston ring and remove by lifting it up at a point just opposite the gap Remove the expander Do not...

Page 67: ...e exhaust port area Measure the cylinder bore at three levels of A B and C in both X and Y directions Avoid the port area Take the maximum figure measured to determine the cylinder bore Service Limit...

Page 68: ...ce Service Limit 0 10mm replace if over Measure the piston pin hole I D Service Limit 12 03mm replace if over Measure the piston pin O D Service Limit 11 98mm replace if below Measure the piston to pi...

Page 69: ...NSTALLATION First install the expander in the second ring groove Then install the top and second rings in their respective ring grooves The piston rings should be pressed into the grooves with even fo...

Page 70: ...iston rings with engine oil and install the piston into the cylinder while compressing the piston rings Install the cylinder head Torque 1 5 1 7kg m Install the exhaust muffler and tighten the exhaust...

Page 71: ..._____________________________________________________________________ ________________________________________________________________________________ _________________________________________________...

Page 72: ...7 A C GENERATOR 7 1 SUPER8 50 2T Torque 3 5 4 0kg m Torque 0 8 1 2kg m Torque 0 6 1 0kg m Torque 0 8 1 2kg m...

Page 73: ...RMATION GENERAL INSTRUCTIONS All A C generator maintenance and inspection can be made with the engine installed Refer to Section 15 for A C generator inspection TORQUE VALUE Flywheel nut 3 5 4 0kg m S...

Page 74: ...emove the three bolts attaching the fan cover to remove the fan cover Remove the cooling fan by removing the four bolts Hold the flywheel with an universal holder and then remove the 10mm flywheel nut...

Page 75: ...crankcase Remove the pulser coil wire clamp from the right crankcase Remove the two bolts attaching the A C generator stator A C GENERATORINSTALLATION Install the A C generator stator and pulser coil...

Page 76: ...f key in the crankshaft keyway Install the flywheel onto the crankshaft with the flywheel groove aligned with the crankshaft woodruff key Hold the flywheel with the universal holder and install the 10...

Page 77: ..._______________________________ ________________________________________________________________________________ ________________________________________________________________________________ KICK S...

Page 78: ...8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY 8 1 SUPER8 50 2T Torque 3 5 4 5kg m Torque 5 0 6 0kg m Torque 3 5 4 0kg m...

Page 79: ...en face I D 34 0 34 25 34 06 Drive belt width 18 17 TORQUE VALUES Drive face nut 3 5 4 0kg m Clutch outer nut 3 5 4 5kg m Clutch drive plate nut 5 0 6 0kg m SPECIAL TOOLS Lock nut wrench 39mm Universa...

Page 80: ...case cover seal rubber for damage or deterioration KICK STARTER SPINDLE REMOVAL Remove the kick lever from the kick starter spindle Remove the circlip and washer from the kick starter spindle Slightly...

Page 81: ...NSPECTION Inspect the kick starter spindle and gear for wear or damage Inspect the return spring for weakness or damage Inspect the kick starter spindle bushing for wear or damage Check the kick start...

Page 82: ...and return spring onto the left crankcase cover Properly install the kick starter driven gear and friction spring as the figure shown If the hooks of the return spring can not be installed properly us...

Page 83: ...COVER INSTALLATION First install the dowel pins and then the seal rubber Install the left crankcase cover and tighten the ten bolts diagonally Connect the drive belt cooling air tube and install the c...

Page 84: ...if below REPLACEMENT Remove the ten left crankcase cover bolts and left crankcase cover 8 4 Hold the clutch outer with the universal holder and remove the 10mm clutch outer nut and clutch outer Hold...

Page 85: ...a new drive belt Set the drive belt on the drive pulley Install the drive pulley face starting ratchet and 12mm washer then tighten the drive face nut Torque 3 5 4 0kg m Clutch Driven Pulley Drive Be...

Page 86: ...ve the 12mm drive face nut Remove the starting ratchet 12mm washer and drive pulley face MOVABLE DRIVE FACE DISASSEMBLY Remove the movable drive face and drive pulley collar from the crankshaft Remove...

Page 87: ...mm replace if below Measure the movable drive face bushing assembly I D Service Limit 20 3mm replace if over Check the drive pulley collar for wear or damage Measure the O D of the drive pulley collar...

Page 88: ...lley 8 8 Remove the starter pinion INSPECTION Inspect the starter pinion seat for wear Inspect the starter pinion for smooth operation Inspect the starter pinion shaft forcing parts for wear and damag...

Page 89: ...and remove the 10mm clutch outer nut Remove the clutch outer Remove the clutch driven pulley Remove the drive belt from the clutch driven pulley CLUTCH DRIVEN PULLEY DIS ASSEMBLY Compress the clutch d...

Page 90: ...de roller pins from the driven pulley and then remove the O rings and oil seal from the driven pulley CLUTCH DRIVEN PULLEY INSPECTION Inspect the clutch outer for wear or damage Measure the clutch out...

Page 91: ...f below Measure the driven face spring free length Service Limit 82 6mm replace if below Check the driven face assembly for wear or damage Measure the driven face O D Service Limit 33 94mm replace if...

Page 92: ...bnormal noise Drive the inner bearing out of the driven pulley face Remove the snap ring and drive the outer bearing out of the driven face Drive a new outer bearing into the driven face with the seal...

Page 93: ...ven face with the mark facing up CLUTCH DRIVEN PULLEY ASSEMBLY First install the movable driven face onto the driven face Then install the guide roller pins O rings and a new oil seal Install the seal...

Page 94: ...e 28mm nut to the specified torque Torque 5 0 6 0kg m CLUTCH DRIVEN PULLEY INSTALLATION Install the drive belt on the clutch driven pulley and then install the clutch driven pulley onto the drive shaf...

Page 95: ...__________________________________________ ________________________________________________________________________________ ____________________________________________________________________________...

Page 96: ...9 FINAL REDUCTION 9 1 SUPER8 50 2T...

Page 97: ...r Crankcase assembly shaft Bearing outer driver 37x40mm Bearing outer driver 32x35mm Bearing driver pilot 17mm Bearing driver pilot 15mm Bearing driver pilot 12mm Bearing outer driver handle A TROUBLE...

Page 98: ...ransmission 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 countershaf...

Page 99: ...he drive shaft and gear for wear or damage Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage Do not remove the transmission...

Page 100: ...remover Remove the final shaft oil seal Drive new bearings into the transmission case cover BEARING REPLACEMENT Left Crankcase Cover Remove the drive shaft Remove the drive shaft oil seal Remove the l...

Page 101: ...new bearings into the left crankcase Install a new drive shaft oil seal FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Install the final gear and final shaft into the left cr...

Page 102: ...the countershaft Install the dowel pins and a new gasket Install the transmission case cover Install and tighten the transmission case cover bolts Install the clutch driven pulley 8 20 Install other...

Page 103: ...hange 0 09 liter Install and tighten the oil check bolt Torque 1 0 1 5kg m Start the engine and check for oil leaks Check the oil level from the oil check bolt hole and add the specified oil to the pr...

Page 104: ..._______________________ _________________________________________________________________________________________ ______________________________________________________________________________________...

Page 105: ...10 CRANKCASE CRANKSHAFT 10 1 SUPER8 50 2T Torque 0 8 1 2kg m...

Page 106: ...embly When separating the crankcase the bearing will remain in the crankcase and it should be removed When assembling drive a new bearing into the crankcase and install a new oil seal SPECIFICATIONS S...

Page 107: ...e crankcase puller on the right crankcase and remove the right crankcase from the left crankcase CRANKSHAFT REMOVAL Attach the crankcase puller on the left crankcase and remove the crankshaft from the...

Page 108: ...PECTION Measure the connecting rod big end side clearance Service Limit 0 6mm replace if over Measure the connecting rod big end radial clearance at two points in the X and Y directions Service Limit...

Page 109: ...The bearings must be replaced if they are noisy or have excessive play CRANKSHAFT INSTALLATION Wash the crankshaft in cleaning solvent and then check for cracks or other faults After check apply clea...

Page 110: ...haft into the left crankcase Bearing Outer Driver Handle Apply KYMCO ULTRA motor oil or molybdenum disulfide to the crankshaft bearings and connecting rod big end Apply grease to the lip of the oil se...

Page 111: ...ket to the crankcase mating surface Assemble the crankcase halves The distance between the right crankcase oil seal and crankcase surface is about 12 5 0 5 mm When installing the oil seal be careful t...

Page 112: ...0 8 SUPER8 50 2T The distance between the left crankcase oil seal and crankcase surface is about 1 0mm Install and tighten the crankcase attaching bolts After assembly check the crankshaft for smooth...

Page 113: ..._______________________________________________________ _________________________________________________________________________________________ CARBURETOR ___________________________________________...

Page 114: ...11 CARBURETOR 11 1 SUPER8 50 2T...

Page 115: ...Idle speed 1850 100rpm Throttle grip free play 2 6mm SPECIAL TOOL Float level gauge TROUBLESHOOTING Engine does not start Lean mixture No fuel in tank Clogged fuel jets Faulty float valve Too much fu...

Page 116: ...r 12 5 Remove the met in box 12 4 Remove the rubber cover Loosen carburetor cap and the throttle valve Disconnect the throttle cable from the throttle valve Remove the throttle valve spring carburetor...

Page 117: ...ALLATION Install the jet needle on the throttle valve and secure with the needle clip Install the rubber seal on the throttle cable and then install the carburetor cap and throttle valve spring Connec...

Page 118: ...e cable free play 3 12 Idle speed adjustment 3 11 Install the met in box CARBURETOR REMOVAL Remove the met in box 12 4 Remove the air cleaner by removing the air cleaner band screw and attaching bolts...

Page 119: ...rminals Resistance 5 10 minutes minimum after stopping the engine If the resistance exceeds 5 replace the auto bystarter with a new one After the engine stops for 30 minutes connect a hose to the fuel...

Page 120: ...and blow the hose with mouth If air can be blown into the hose the auto bystarter is faulty and replace it with a new one AUTO BYSTARTER REMOVAL Remove the auto bystarter cover Remove the two auto bys...

Page 121: ...e carburetor body until it bottoms Install the set plate and then tighten the two screws FLOAT CHAMBER Remove the two float chamber screws and the float chamber Remove the screw and O ring Remove the...

Page 122: ...moving the throttle stop screw or air screw record the number of rotations until it seats lightly Then remove them Remove the main jet and needle jet holder CARBURETOR PASSAGES CLEANING Blow compresse...

Page 123: ...EL INSPECTION Slightly tilt the carburetor and measure the float level with the float valve just connecting the float arm Float Level 8 6mm Replace the float if the level is out of the specified level...

Page 124: ...ew Opening 1 turns Start the engine and turn the air screw in or out slowly to obtain the highest engine speed Turn the throttle stop screw to obtain the specified idle speed Idle Speed 1950 100rpm Sl...

Page 125: ...clearance between the seat and reed Replace the valve if necessary INSTALLATION Install the reed valve in the reverse order of removal Install a new gasket with the gasket indentation aligned with the...

Page 126: ...emove the rear carrier 12 5 Disconnect the fuel tube and vacuum tube at the auto fuel tank Disconnect the fuel unit wire connector Remove the fuel tank holder mounting bolts and fuel tank Inspect the...

Page 127: ..._________________________________________________________________ ________________________________________________________________________________ _____________________________________________________...

Page 128: ...12 FRAME COVERS 12 1 SUPER8 50 2T ASSEMBLY DRAWING...

Page 129: ...e the cover joint claws may be damaged Items Related for Removal Handlebar front cover Headlight wire Front cover Handlebar rear cover Speedometer cable and instrument light wire connectors etc Frame...

Page 130: ...ve the two bolts and four nuts attaching the met in box Remove the met in box Remove the three bolts attaching the rear carrier Remove the rear carrier FRAME BODY COVER REMOVAL Remove the one nuts att...

Page 131: ...cover Remove the center cover Remove the body cover FLOOR FOOT REMOVAL Remove the screws attaching the right and left side covers Remove the right and left side covers by pulling them outward Disconne...

Page 132: ...ove the floor foot Remove the front upper cover Remove the eight screws attaching the leg shield low Disconnect the leg shield low with the cowl under cover The installation sequence is the reverse of...

Page 133: ...e four bolts attaching the front windshield out cover Remove the windshield out cover Remove the windshield HANDLEBAR COVER REMOVAL First remove the windshield Remove the four screws and two bolts att...

Page 134: ...e the handlebar cover The installation sequence is the reverse of removal BOTTOM COVER REMOVAL Remove the four bolts attaching the bottom cover Remove the bottom cover F RONT FENDER AND UNDER COWL REM...

Page 135: ...k nuts from joint in the exhaust muffler Remove the exhaust muffler two lock bolts to remove the exhaust muffler Remove the exhaust muffler joint packing collar The installation sequence is the revers...

Page 136: ...ER FRONTFORK 13 0 SUPER8 50 2T 13 FRONT WHEEL FRONT BRAKE FRONT SUSPENSION SERVICE INFORMATION 13 2 TROUBLESHOOTING 13 3 FRONT WHEEL 13 4 HYDRAULIC BRAKE DRAWING 13 7 HYDRAULIC BRAKE 13 8 FRONT SHOCK...

Page 137: ...13 STEERINGHANDLEBAR FRONTWHEEL FRONTBRAKE FRONTSHOCK ABSORBER FRONTFORK 13 1 SUPER8 50 2T 4 5kg m 6 0kg m...

Page 138: ...m use shop towels to cover and protect rubber plastic parts and coated surfaces Wipe off any spilled brake fluid with a clean shop towel Inspect the brake system before riding SPECIFICATIONS Item Stan...

Page 139: ...not track straight Improperly tightened axle nut Uneven front shock absorbers Soft front shock absorber Bent front fork Weak shock springs Bent front axle or uneven tire Insufficient damper oil Poor b...

Page 140: ...xle nut and pull out the axle Remove the front wheel Remove the front brake panel INSPECTION AXLE RUNOUT Set the axle in V blocks and measure the runout using a dial gauge The actual runout is 1 2 of...

Page 141: ...e races do not turn smoothly quietly or if they fit loosely in the hub BEARING REPLACEMENT Remove the front wheel bearings and distance collar Bearing Remover Bearing Remover Head 12mm Pack all bearin...

Page 142: ...hub cutouts Apply a thin coat of grease to the axle shaft Install the front wheel by aligning the brake panel groove with the front fork tab Insert the axle shaft Install and tighten the axle nut Torq...

Page 143: ...13 STEERINGHANDLEBAR FRONTWHEEL FRONTBRAKE FRONTSHOCK ABSORBER FRONTFORK 13 7 SUPER8 50 2T HYDRAULIC BRAKE DRAWING...

Page 144: ...the two bolts attaching the brake caliper Remove the brake caliper Compress the brake caliper seat and press down the fixed reed to take out the brake pads When operating the brake lever the brake res...

Page 145: ...e system DISASSEMBLY Remove the piston rubber cover and snap ring from the brake master cylinder Remove the main piston and spring from the brake master cylinder Clean the inside of the master cylinde...

Page 146: ...and 2nd rubber cups for wear or damage 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 147: ...aling washers Install the handlebar covers Connect the front and rear stop switch wire connectors Fill the brake reservoir with recommended brake fluid to the upper limit and bleed air according to th...

Page 148: ...tion caused by the removed pistons Check each piston cylinder for scratches or wear and replace if necessary Push the piston oil seals outward to remove them Clean each oil seal groove with brake flui...

Page 149: ...tall the brake caliper seat INSTALLATION Install the brake caliper and tighten the two bolts Torque 2 9 3 5kg m Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt Torque...

Page 150: ...ck absorbers onto the steering stem Install and tighten the front shock absorber upper mount bolts Tighten the lower mount bolts Install the front wheel STEERING HANDLEBAR REMOVAL Remove the handlebar...

Page 151: ...eat from the handlebar and disconnect the throttle cable from the throttle pipe Remove the throttle pipe from the handlebar Remove the steering stem lock bolt collar nut and the handlebar STEERING STE...

Page 152: ...BALL RACE REPLACEMENT Drive out the top and bottom ball races Drive new top and bottom ball races into the steering head using the outer driver Outer Driver INSTALLATION Install the top and bottom st...

Page 153: ...g stem right and left several times to make steel balls contact each other closely Install the steering stem lock nut and tighten it while holding the top cone race Torque 7 0 8 0kg m Install the fron...

Page 154: ..._____________________________________________________________ ________________________________________________________________________________ _________________________________________________________...

Page 155: ...14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER 14 1 SUPER8 50 2T 2 7kg m 0 6kg m 11 0kg m 2 2kg m 4 0kg m 3 3kg m...

Page 156: ...r shock absorber upper mount bolt 3 5 4 5kg m Rear shock absorber lower mount bolt 2 4 3 0kg m SPECIAL TOOL Rear shock absorber remover Rear shock absorber compressor TROUBLESHOOTING Rear wheel wobbli...

Page 157: ...ove the exhaust muffler Remove the rear axle nut to remove the rear wheel INSPECTION Measure the rear wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over INSTALLAT...

Page 158: ...rake drum I D Service Limit 95 5mm replace if over BRAKE LINING INSPECTION Measure the brake lining thickness Service Limit 2 0mm replace if below REAR BRAKE DISASSEMBLY Remove the rear brake adjustin...

Page 159: ...install it Apply engine oil to the felt seal and install it to the brake cam Install the wear indicator plate Install the brake arm onto the brake cam Install and tighten the brake arm bolt Install th...

Page 160: ...e met in box 12 5 Remove the air cleaner case 5 2 Remove the rear shock absorber upper and lower mount bolts to remove the rear shock absorber INSTALLATION Install the rear shock absorber Install the...

Page 161: ...__________________________________________________ _________________________________________________________________________________________ ___________________________________________________________...

Page 162: ...rging Standard 0 4A 5H Battery current Quick 4A 0 5H Spark plug NGK BR8HSA Spark plug gap 0 6 0 7mm Primary coil 0 2 0 3 Secondary coil with plug cap 7 0 8 4K Ignition coil resistance Secondary coil w...

Page 163: ...plug Faulty ignition switch Poorly insulated plug cap Faulty ignition coil Improper ignition timing Faulty CDI unit Battery voltage too low 6V max Faulty A C generator Faulty CDI unit STARTING SYSTEM...

Page 164: ...15 ELECTRICAL EQUIPMENT 15 3 SUPER8 50 2T CHARGING SYSTEM A C Generator Dimmer Switch Ignition Switch Resistor...

Page 165: ...ry negative cable Charging current Standard 0 4A Quick 4A Charging time Standard 5 hours Quick 0 5 HOUR After charging Open circuit voltage 12 8V min Battery Cover First disconnect the battery negativ...

Page 166: ...e speed to test the output Position RPM Day Night 2500 1 3A min 1 0A min 6000 2 0A min 2 0A min Charging Limit Voltage 14 5 0 5V 8000rpm If the limit voltage is not within the specified range check th...

Page 167: ...rminals Replace the regulator rectifier if the readings are not within the specifications in the table below Model Brand Range SP 10D Sanwa K TH 5H Kowa 100 Due to the semiconductor in circuit it is n...

Page 168: ...N SYSTEM Ignition Coil Ignition Switch Spark Plug A C Generator Exciter Coil CDI Unit Ignition Switch G Battery B L Y W G V L Fuse 5 12W Ignition Coil G G Fuse Spark Plug REG REC Light control G AUTO...

Page 169: ...3 0 187 Measure the secondary coil resistance between the spark plug cap and the primary coil terminal as Figure A shown Resistance 20 with plug cap 10 14K Measure the secondary coil resistance betwee...

Page 170: ...rmal and continuous spark Faulty Weak or intermittent spark A C GENERATOR Exciter Coil Pulser Coil Inspection Remove the met in box 12 4 Disconnect the A C generator wire connector Measure the pulser...

Page 171: ...ow Green Black Yellow Black 4 7M 4 7M 2 3M Blue Yellow 15 20K 600 900 1000 1500K Green 15 20M 600 900 4 7M Black Yellow Due to the semiconductor in circuit it is necessary to use a specified tester fo...

Page 172: ...15 ELECTRICAL EQUIPMENT 15 11 SUPER8 50 2T STARTING SYSTEM Starter Button Starter Motor Ignition Switch Starter Relay...

Page 173: ...battery positive terminal and the relay C terminal to the battery negative terminal Check for continuity between the starter relay A and B terminals The relay is normal if there is continuity STARTER...

Page 174: ...TARTER MOTOR INSPECTION Connect a battery across the starter motor and check for its operation 1 Do not turn the starter motor for a long time 2 This inspection should be done with a fully charged bat...

Page 175: ...________________ _________________________________________________________________________________________ _________________________________________________________________________________________ INS...

Page 176: ...fficient Burned bulb Fuse burned out Faulty switch Dead battery Broken or shorted wire Faulty ignition switch Fuse burned out Faulty instrument Weak battery Faulty oil meter Poorly connected wire Faul...

Page 177: ...Wire Terminals Upper Lower G Y W 20 40 560 580 FUEL GAUGE INSPECTION Connect the fuel unit wire connectors and turn the ignition switch ON Check the fuel gauge needle for correct indication by moving...

Page 178: ...tance Green Red Black 46 Green Black Oil Meter Operation Inspection Connect the oil meter wire connectors and turn the ignition switch ON Measure the resistance between the wire terminals with the flo...

Page 179: ...the wire terminals Color Red Black White Green Black Symbol BAT1 IG E BAT2 LOCK OFF ON IGNITION SWITCH REPLACEMENT Remove the front cover 12 3 Disconnect the ignition switch wire couplers Remove the...

Page 180: ...NSPECTION Check for continuity between wire terminals Color W L L We Y Symbol HL HI LO BAT HI LO PASSING TURN SIGNAL SWITCH INSPECTION Check for continuity between the wire terminals Color SB O GR Sym...

Page 181: ...TCH INSPECTION Check for continuity between wire terminals Push the horn button when measuring Color Light Green Brown Blue Symbol HO BAT FREE PUSH STOP SWITCH INSPECTION Remove the handlebar front co...

Page 182: ...SIGNAL LIGHT REPLACEMENT Remove three screws attaching the turn signal light set and remove the light set TAILLIGHT STOPLIGHT REAR TURN SIGNAL LIGHT BULB REPLACEMENT Taillight Base Removal Remove the...

Page 183: ...cable Remove the instrument bulb sockets Disconnect the two fuel gauge wires Remove the instrument wire clamp screw Remove the three screws attaching the instruments to the handlebar rear cover Remove...

Page 184: ...__________________ ________________________________________________________________________________ ________________________________________________________________________________ EXHAUSTEMISSIONCONT...

Page 185: ...g the operation of the air injection cut off valve Air Injection Cut off Valve Prevent exhaust muffler noise and backfiring at sudden deceleration The air injection cut off valve usually opens to lead...

Page 186: ...Faulty air cut off valve 5 Leaking vacuum tube Exhaust muffler noise 1 Faulty air injection cut off valve 2 Broken vacuum tube 3 Faulty reed valve SERVICE INFORMATION GENERAL INSTRUCTIONS During opera...

Page 187: ...new one when the filter elements obstruct considerable dirt INSTALLATION The installation sequence is the reverse of removal The secondary air cleaner must be assembled and installed properly to avoi...

Page 188: ...ON Check the reed valve for cracks damage big clearance or weak reeds Replace if necessary Check the gasket and O ring for damage or deterioration and replace if necessary Reed valve stopper clearance...

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