1. GENERAL INFORMATION SUPER8 50 1 - nazwa.pl · Tool boox E033 Special tools storage Tappet adjuster E036 90012 screw tappet 3-5 7-7 Valve spring compressor E038 Valve spring 7-8

1. GENERAL INFORMATION

1-1

SUPER8 50

Location of Engine Serial Number

Frame Serial Number

1

ENGINE SERIAL NUMBER

1ENGINE 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


1-2

SUPER8 50

SPECIFICATIONS

Motorcycle Name & Type SUPER8 50Name & Model No. LEJ2Overall length (mm) 1940Overall width (mm) 745Overall height (mm) 1220Wheel base (mm) 1365Engine type O.H.C.Displacement 50ccFuel Used 92# nonleaded gasoline

Front wheel 43Net weight (kg) Rear wheel 55

Total 108Front wheel 45

Gross weight(kg) Rear wheel 67Total 144

Front wheel 100/80 -14 56JTires Rear wheel 120/80 -14 56JGround clearance (mm) 112

Perform- Braking distance (m) 4 (Initial speed20km/h)

ance Min. turning radius (m) 1.99

Starting system Starting motor &kick starter

Type Gasoline, 4-strokeCylinder arrangement Single cylinderCombustion chamber type Semi-sphereValve arrangement O.H.C.Bore x stroke (mm) φ39.0 x 41.4Compression ratio 11Compression pressure(kg/cm²-rpm) 18Max. output 2.4/7500kw/(r/min)Max. torque 3.2/7000kg m/rpm

Open 3°Port

IntakeClose 7°

Engine

timing Open 9°Exhaust Close 1°

Valve clearance Intake 0.04(cold) (mm) Exhaust 0.04Idle speed (rpm) 1900±100rpm

Lubrication type Forced pressure &wet sump

Oil pump type Inner/outer rotor typeOil filter type Full-flow filtration

LubricationSystem

Oil capacity 0.8 literCooling Type Forced air cooling

Air cleaner type & No Paper element, wetFuel capacity 6.0 liter

Type CVKPiston dia. (mm) 18Venturi dia.(mm) φ18.5equivalent

Carburetor Throttle type Butterfly type

Type CDIIgnition timing BTDC28°/4000rpmContact breaker Non-contact point type

Spark plug NGK C7HSA

Spark plug gap 0.6～0.7mmBattery Capacity 12V7AHClutch Type Dry multi-disc clutch

Type Non-stage transmission

Operation Automatic centrifugaltype

Type Two-stage reductionReduction 1st 0.8-3.1ratio 2nd 11.05

Front Caster angle 27°Axle Trail length ⎯

Tire pressure Front 1.75(kg/cm²) Rear 2.25Turning Left 45°angle Right 45°

Front DISK (180mm) brakeBrake systemtype Rear Drum (110mm) brake

Front TELESCOPESuspension typeRear Unit SwingFront 80Shock absorber

distance Rear 82Frame type Under Bone

Fuel SystemElectrical Equipm

ent

Ignition System

Power D

rive System

Transmis-

sion Gear

Reduction

Gear

Moving D

eviceD

amping

Device


1-3

SUPER8 50

SERVICE PRECAUTIONS

Make sure to install new gaskets, O-rings,circlips, cotter pins, etc. whenreassembling.

When tightening bolts or nuts, begin withlarger-diameter to smaller ones at severaltimes, and tighten to the specified torquediagonally.

Use genuine parts and lubricants

.

When servicing the motorcycle, be sure touse special tools for removal andinstallation.

After disassembly, clean removed parts.Lubricate sliding surfaces with engine oilbefore reassembly.


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SUPER8 50

Apply or add designated greases andlubricants to the specified lubricationpoints.

After reassembly, check all parts for propertightening and operation.

When two persons work together, payattention to the mutual working safety.

Disconnect the battery negative (-) terminalbefore operation.When using a spanner or other tools, makesure not to damage the motorcycle surface.

After operation, check all connectingpoints, fasteners, and lines for properconnection and installation.When connecting the battery, the positive(+) terminal must be connected first.After connection, apply grease to thebattery terminals.Terminal caps shall be installed securely.


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SUPER8 50

If the fuse is burned out, find the cause andrepair it. Replace it with a new oneaccording to the specified capacity.

After operation, terminal caps shall beinstalled securely.

When taking out the connector, the lock onthe connector shall be released beforeoperation.

Hold the connector body when connectingor disconnecting it.Do not pull the connector wire.

Check if any connector terminal is bending,protruding or loose.

ConfirmCapacity


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SUPER8 50

The connector shall be insertedcompletely.If the double connector has a lock, lockit at the correct position.Check if there is any loose wire.

Before connecting a terminal, check fordamaged terminal cover or loosenegative terminal.

Check the double connector cover forproper coverage and installation.

Insert the terminal completely.Check the terminal cover for propercoverage.Do not make the terminal cover openingface up.

Secure wire harnesses to the frame withtheir respective wire bands at thedesignated locations.Tighten the bands so that only the insulatedsurfaces contact the wire harnesses.

Snapping!


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SUPER8 50

After clamping, check each wire to makesure it is secure.

.

Do not squeeze wires against the weld orits clamp

After clamping, check each harness tomake sure that it is not interfering with anymoving or sliding parts.

When fixing the wire harnesses, do notmake it contact the parts which willgenerate high heat.

Route wire harnesses to avoid sharp edgesor corners. Avoid the projected ends ofbolts and screws.Route wire harnesses passing through theside of bolts and screws. Avoid theprojected ends of bolts and screws.

No Contact !


1-8

SUPER8 50

Route harnesses so they are neitherpulled tight nor have excessive slack.

.

Protect wires and harnesses with electricaltape or tube if they contact a sharp edge orcorner

When rubber protecting cover is used toprotect the wire harnesses, it shall beinstalled securely.

Do not break the sheath of wire.If a wire or harness is with a broken sheath,repair by wrapping it with protective tapeor replace it.

When installing other parts, do not press orsqueeze the wires.

Do not pulltoo tight!

Do not press orsqueeze the wire.


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SUPER8 50

After routing, check that the wire harnessesare not twisted or kinked.

Wire harnesses routed along withhandlebar should not be pulled tight, haveexcessive slack or interfere with adjacentor surrounding parts in all steeringpositions.

When a testing device is used, make sure tounderstand the operating methodsthoroughly and operate according to theoperating instructions.

Be careful not to drop any parts.

When rust is found on a terminal, removethe rust with sand paper or equivalentbefore connecting.

Do not bend or twist control cables.Damaged control cables will not operatesmoothly and may stick or bind.

Do you understandthe instrument? Isthe instrument setcorrectly?

Remove Rust !


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SUPER8 50

Symbols:The following symbols represent theservicing methods and cautions included inthis service manual.

: Apply engine oil to thespecified points. (Usedesignated engine oil forlubrication.)

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Use special tool.

: Caution

: Warning

( 12-3) : Refer to page 12-3.

Engine Oil

Grease

Gear Oil

Special

＊


1-11

SUPER8 50

TORQUE VALUES

STANDARD TORQUE VALUESItem Torque (kg-m) Item Torque (kg-m)

5mm bolt, nut6mm bolt, nut8mm bolt, nut10mm bolt, nut12mm bolt, nut

0.45-0.60.6-1.21.8-2.53.0-4.05.0-6.0

5mm screw6mm screw, SH bolt6mm flange bolt, nut8mm flange bolt, nut10mm flange bolt, nut

0.35-0.50.7-1.11.0-1.42.4-3.03.5-4.5

Torque specifications listed below are for important fasteners.

ENGINE

Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks

Cylinder head bolt ACylinder head bolt BOil filter screen capExhaust muffler lock boltCylinder head flange nutValve adjusting lock nutCam chain tensioner slipper boltOil boltClutch outer nutClutch drive plate nutStarter motor mounting boltOil pump boltDrive face nutSpark plugA.C. generator stator boltCam chain tensioner bolt

2412421111231121

66

3067388

102864

101066

0.7-1.10.7-1.11.0-2.00.7-1.11.2-1.6

0.07-0.090.4-0.71.1-1.53.5-4.55.0-6.00.8-1.20.1-0.35.5-6.51.0-1.40.8-1.20.8-1.2

Double end bolt

Double end boltApply oil tothreads

FRAME

Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks

Steering stem lock nutFront axle nutRear axle nutRear shock absorber upper boltRear shock absorber lower boltSpeedometer cable set screwRear shock absorber lock nut

1111111

25.4101410858

8.0-12.05.0-7.0

11.0-13.04.0-5.02.0-3.0

0.45-0.63.0-3.6

U-nutU-nutU-nut

Apply locking agent


1-12

SUPER8 50

SPECIAL TOOLS

Tool Name Tool No. Remarks Ref. Page10-310-4Bearing puller 10.12.15.18 mm E037 10.12.15.18mm bearing12-6

Bushing remover L E032 11102 bush engine hanger rubber

Bushing remover S EO19 11203 bush rear cushion under rubber

Crankshaft bearing puller E030 91005 radial bearing

Crankshaft protector E029 13000 crankshaft comp 12mm.14mm

Clutch spring compressor E027 2301a driven pully assy9-99-12

Cushion assemble & disassembletool F004 52400 cushion assy 13-4

Flywheel holder E017 31110 flywheel comp.2310a pully assydriven

9-59-99-1314-714-9

Flywheel puller E002 Left hand thread 27mm 14-7

Long socket wrench 32mm 8angle F002 50306 steering stem 12-2112-22

Oil seal & bearing installer E014 Oil seal & bearing install

Tool boox E033 Special tools storage

Tappet adjuster E036 90012 screw tappet 3-5

7-7Valve spring compressor E038 Valve spring 7-8


1-13

SUPER8 50

LUBRICATION POINTS

ENGINE

Lubrication Points Lubricant

Valve guide/valve stem movable part Cam lobes Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting 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-ring face Oil seal lip

•Genuine KYMCO Engine Oil (SAE15W-40) •API−SG Engine Oil

Starter idle gear Friction spring movable part/shaft movable part Shaft movable grooved part Kick starter spindle movable part

High-temperature resistant grease

A.C. generator connector Transmission case breather tube

Adhesive


1-14

SUPER8 50

FRAMEThe following is the lubrication points for the frame.Use general purpose grease for parts not listed.Apply clean engine oil or grease to cables and movable parts not specified.This will avoid abnormal noise and rise the durability of the motorcycle.

Rear Wheel Bearings

Main Stand Pivot

Speedometer Gear/ Front WheelBearings/ Brake Cam/ Anchor Pin/Front Shock Absorber LowerMount Bushings/Pivot

Grease

Grease

Grease

Engine OilRear Brake Cable

Brake Cam/Anchor Pin

Grease

GreaseFront Brake LeverPivot

Front Brake Cable/Speedometer Cable/Throttle Cable

Engine/ Oil


1-15

SUPER8 50

CABLE & HARNESS ROUTING

Front Stop Switch Wire Rear Stop Switch Wire

Throttle Cable

Regulator/Rectifier

Rear Brake Cable

Speedometer Cable

Horn

Ignition Switch

Winker

Front Brake Fluid Tube

Brake Master Cylinder


1-16

SUPER8 50

Regulator/Rectifier

Speedometer Cable

Ignition Switch

Throttle Grip

Rear Brake Lever

Front Brake Fluid Tube

Headlight Resistor

Horn

Control Lighting


1-17

SUPER8 50

Starter Relay

Fuse

Battery (+) Cable

Battery (-) Cable

CDI Unit

Fuel Tank

Ignition Coil


1-18

SUPER8 50

Throttle CableVacuum Tee

CarburetorOverflow Tube

Fuel Tube

Crankcase BreatherTube

Ignition CoilPrimary Wire

Ignition Wire

Fuel Filter

Auto Cock Assy Fuel


1-19

SUPER8 50

Throttle Cable

Fuel Tube

Vacuum Tube

Auto Bystarter

Crankcase Breather Tube

Wire

Crankcase Breather Tube

Throttle Cable

Vacuum Tube

Fuel Unit

Reed Valve

Secondary AirInlet Tube

Air InjectionCut-offValve

Ignition Coil


1-20

SUPER8 50

WIRING DIAGRAM


1-21

SUPER8 50

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

Empty fuel tankClogged fuel line between fueltank and carburetorClogged float oil passageClogged fuel tank cap breatherholeClogged fuel filterClogged fuel strainerFaulty auto fuel valve

Faulty spark plugFouled spark plugFaulty CDI unitFaulty pulser coilBroken or shorted ignition coilBroken or shorted high-tensionwireFaulty ignition switch

Faulty starter clutchValve clearance too smallImproper valve and seat contactWorn cylinder, piston and pistonringsLeaking cylinder head gasketSeized valveImproper valve timing

Faulty auto bystarterAir leaking through intake pipeIncorrect ignition timingIncorrectly adjusted pilot screw

Flooded carburetorFaulty auto bystarterThrottle valve excessively open

Check if fuel reachescarburetor by looseningdrain screw

Remove spark plug andinstall it into spark plugcap to test spark byconnecting it to engineground

Inspection/Adjustment Probable Cause

Spark jumps

Normal compression

Engine does not fire

Weak or no spark

Low or no compression

Engine fires but does not start

Test cylindercompression

Start engine by follow-ing normal startingprocedure

Remove spark plug andinspect again

Symptom

Fuel reaches carburetor

Fuel does not reach carburetor

Wet spark plugDry spark plug


1-22

SUPER8 50

ENGINE LACKS POWER

Clogged air cleanerPoor quality fuel (Restricted)Clogged fuel tank cap breather holeClogged exhaust mufflerFaulty auto bystarterSplit carburetor vacuum pistondiaphragmFaulty auto fuel valve

Faulty CDI unit Faulty pulser coil

Improper valve clearanceadjustmentWorn valve seat (valve stem tooprotruding

Improper valve and seat contactWorn cylinder and piston ringsLeaking cylinder head gasketImproper valve timing

Clogged carburetor jets

Fouled spark plugIncorrect heat range plug

Oil level too highOil level too lowOil not changed

Clogged oil pipe

Faulty oil pump

Worn cylinder and piston ringsMixture too leanPoor quality fuelExcessive carbon buildup incombustion chamberIgnition timing too early

Excessive carbon build-up incombustion chamberPoor quality fuelClutch slippingMixture too leanIgnition timing too early

Start engine and acceleratelightly for observation

Inspection/Adjustment Symptom Probable Cause

Engine speedincreases

Correct timing

Engine speed does notincrease sufficiently

Incorrect timing

Check ignition timingusing a timing light

Test cylinder compression

Check carburetor forclogging

Rapidly accelerate or runat high speed

Remove spark plug andinspect

Check if engine overheats

Check valve clearance

Correct Incorrect

Normal compression

Abnormal compression

Remove oil dipstick andcheck oil level and condition

Remove cylinder head oilpipe bolt and inspect

Engine overheats Engine does not overheats

Plug not fouled ordiscolored

Plug fouled or discolored

Correct and not contaminated

Incorrect or contaminated

Valve train lubricatedproperly

Valve train notlubricated properly

Engine does not knock Engine knocks

Not clogged Clogged


1-23

SUPER8 50

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Faulty CDI unitFaulty pulser coil

Mixture too rich (turn screwout)Mixture too lean (turn screw in)

Deteriorated O-ringCarburetor not securelytightenedDamaged insulator rubberBroken vacuum tube

Faulty or fouled spark plugFaulty CDI unitFaulty A.C. generatorFaulty ignition coilBroken or shorted spark plugwireFaulty ignition switch

Faulty air cut-off valveDamaged vacuum tubeClogged or damaged air venthole

Remove spark plug andinstall it into spark plugcap to test spark byconnecting it to engineground


Check ignition timing

Check air cut-off valve

Check carburetor gasketfor air leaks

Check carburetor pilotscrew adjustment

Correct timing Incorrect timing

Correctly adjusted

No air leak Air leaks

Good spark Weak or inter- mittent spark

Good Faulty

Incorrectly adjusted


1-24

SUPER8 50

POOR PERFORMANCE (AT HIGH SPEED)

Faulty CDI unitFaulty pulser coil

Improperly adjusted valve clearanceWorn camshaftWorn valve seat

Empty fuel tankClogged fuel tube or filterFaulty charcoal canisterFaulty auto fuel valve

Clean and unclog

Cam timing gear aligning marksnot aligned

Faulty spring


Check ignition timing

Check carburetor jetsfor clogging

Check fuel pump forfuel supply

Correct timing Incorrect timing

Check valve springtension

Check valve clearance

Fuel flows freely Fuel flow restricted

Correct Incorrect

Not clogged Clogged

Correctly adjusted Incorrectly adjusted

Not weakened Weak spring

Check valve timing


1-25

SUPER8 50

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)

Undercharging

Dead batteryFaulty battery

Faulty A.C. generator coilBroken yellow wireLoose connector

Broken red wire

Faulty regulator/rectifierPoorly connected coupler

Faulty A.C. generator

Overcharging

Broken green wire

Poorly connected coupler

Faulty regulator/rectifier

Start engine and testlimit voltage betweenbattery terminals

Connect battery (+) wireto regulator/rectifiercoupler red wire andbattery (-) wire to engineground and test voltage

Inspection/Adjustment

Inspection/Adjustment

Symptom

Symptom

Probable Cause

Probable Cause

Normal voltage

Battery has voltagewith ignitionswitch “ON”

Normal

Voltage does notincrease

Battery has novoltage with ignitionswitch “ON”

Resistance too high

Normal voltage No voltage

Measure resistancebetween AC generatorcoil terminals

Normal Abnormal

Check regulator/rectifiercoupler for looseconnection

Normal Abnormal

Connect battery (+) wireto regulator/rectifiercoupler green wire andbattery (-) wire to engineground and test voltage

Check regulator/rectifiercoupler for looseconnection


1-26

SUPER8 50

NO SPARK AT SPARK PLUG

Faulty old spark plug

Loose spark plug cap

Poorly connected coupler

Faulty ignition switchFaulty pulser coilFaulty ignition coil

Broken wire harnessPoorly connected coupler

Faulty CDI unit

Faulty ignition coil

Replace with a newspark plug and inspectagain

Check CDI unit couplerfor looseness


Normal

Abnormal

Normal

Abnormal

Normal Abnormal

Abnormal

Measure resistancebetween CDI unitcoupler wire terminals

Check related parts

Check ignition coil witha CDI unit tester

Weak or no spark

Not loose

Good spark

Loose

Good Good

Check spark plug capand high-tension wirefor looseness

Check CDI unit with aCDI unit tester

Documents

1. GENERAL INFORMATION SUPER8 50 1 - nazwa.pl · Tool boox E033 Special tools storage Tappet adjuster E036 90012 screw tappet 3-5 7-7 Valve spring compressor E038 Valve spring 7-8