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Service Manual - Kymco Spare Parts

1. 10 4 CRANKSHAFT INSTALLATION 10 5 68 ca Lv 10 7 10 0 10 CRANKCASE CRANKSHAFT SUPERS 50 2T Torque 0 8 1 2kg m 10 1 10 CRANKCASE CRANKSHAFT SUPER8502T _ SERVICE INFORMATION GENERAL INSTRUCTIONS e This section covers crankcase separation to service the crankshaft e The following parts must be removed before separating the crankcase Engine Section 5 Driven pulley 9 Carburetor Section 11 A C generator Section 7 Oil pump Section 4 Cylinder head cylinder Section 6 Reed valve Section 11 e When the left crankcase must be replaced remove the following part in addition to the above Final reduction removal e Special tools must be used for crankshaft and crankcase assembly 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 SUPERS 50 2T Item Standard mm Service Limit mm Connecting rod big end side clearance Connecting rod big end radial 0 04 clearance l Crankshaft runout A B 7 0 15 0 10 SPECIFICATIONS SPECIAL TOOLS Crankcase puller Bearing outer driver handle A Universal bearing puller Bearing outer driver 42x47mm Crankcase assembly collar Bearing driver pilot 20mm Cran
2. 4 6 4 0 SUPER8 50 2T 4 LUBRICATION SYSTEM LUBRICATION SYSTEM 4 1 4 LUBRICATION SYSTEM SUPERS 50 2T SERVICE INFORMATION GENERAL INSTRUCTIONS e Use care when removing and installing the oil pump not to allow dust and dirt to enter the engine and oil line e Do not attempt to disassemble the oil pump e Bleed air from the oil pump if there is air between the oil pump oil line e If the oil is disconnected refill the oil line with motor oil before connecting it SPECIFICATIONS e Recommended Motor Oil 2 stroke Motor Cil e Oil Capacity 1 1 liter Light comes on 0 5 liter TROUBLESHOOTING Excessive white smoke or carbon deposits on spark plug e Oil pump not properly synchronized excessive oil e Poor quality oil Engine overheating e Oil pump not properly adjusted insufficient oiling Poor quality oil Seized piston e No oil in tank or clogged oil line e Oil pump not properly adjusted insufficient oiling e Air in oil line e Faulty oil pump Cil not flowing out of tank to engine Clogged oil tank cap breather hole e Clogged oil filter 4 2 4 LUBRICATION SYSTEM SUPERS 50 2T OIL PUMP REMOVAL Oil Pump Control Cable Do allow foreign matters to enter the crankcase Before removing the oil pump clean the oil pump and crankcase surfaces Remove the met in box 212 4 Disconnect the oil pump control cable from the pump body
3. Testcylinder compression using a compression gauge Worn cylinder and piston rings Norm Abnormal Q Blown cylinder head gasket compression compression Flaws in cylinder head Faulty reed valve Seized piston Check carburetor for clogging Not Clogged Clogged Clogged carburetor jets Check ignition timing gt m TE Q Faulty CDI unit Correct timing Incorrect timing enerator flywheel not aligned Check carburetor air screw adjustment Mixture too rich turn screw Correctly adjusted Incorrectly adjusted ou Mixture too lean turn screw in 4 2 22 2 GENERAL INFORMATION SUPERS 50 2T Inspection Adjustment Symptom Probable Cause Check carburetor gasket for air leaks Carburetor not securely tightened No air leak Air leaks Faulty intake manifold asket Deformed or broken carburetor O ring Removeauto bystarter connecting wire and check if bypass fuel line is clogged Q Broken cable Not clogged Clogged to Dirty auto bystarter Faulty auto bystarter Connect auto
4. Q Incorrect heat range plug Mixture too lean discolored discolored Engine does Engine overheats overheats PA re rai or i run at high speed Poor quality fuel Engine does not knock Engine knocks Excessive carbon build up in combustion chamber Ignition timing too early Excessive carbon build up in combustion chamber Poor quality fuel r 9 Clutch slipping Mixture too lean 2 24 2 GENERAL INFORMATION SUPERS 50 2T POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Symptom Probable Cause Check ignition timing gt m Faulty CDI unit Correct timing Incorrect timing Faulty A C generator Check carburetor air screw adjustment DUE too rich turn screw t Correctly adjusted Incorrectly adjusted ou Mixture too lean turn screw in Check carburetor gasket for air leaks gt O K cint not securely i i ightene areas Aras Faulty intake manifold Remove spark plug asket and install it into 9 Deformed carburetor O spark plug cap to test ring spark by connecting it to engine ground Faulty or
5. Ignition coil resistance with plug cap 6 99 10 21 Secondary without plug 3 24 3 96KQ Pulser coil resistance 20 C 80 16002 Ignition timing 13 1 BTDC 2000rpm 2 11 2 GENERAL INFORMATION SUPERS 50 2T TORQUE VALUES ENGINE Cylinder head bolt BF7x115 Clutch drive plate nut 10 Clutch outer nut NH10 Drive face nut NH12 Oil check bolt 10 Engine mounting bolt BF10x95 Engine hanger bracket bolt BF10x50 Exhaust muffler joint lock nut M8mm Exhaust muffler lock bolt BF8x35 ltem Thread dia mm Torque kg m Handlebar lock nut 4 5 5 0 Flange bolt U nut Steering stem lock nut 7 0 8 0 Steering top cone race 0 5 1 3 Front axle nut 5 0 7 0 Flange U nut Rear axle nut 11 0 13 0 Flange U nut Rear brake arm bolt Front shock absorber upper mount 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 Flange nut Flange bolt U nut Cross head Apply locking agent Flange screw U nut Flange nut Torque specifications listed above are for important fasteners Others should be tightened to standard torque values below STANDARD TORQUE VALUES SH bolt 8mm Flange 6mm bolt Torque kg m Torque kg m 5mm bolt nut 5mm screw 6mm bolt nut 6mm screw SH bolt 8mm bolt nut 6mm flange bolt nut 10mm bolt nut 8mm flange bolt nut 12mm bolt nu
6. iz LL UU JY T 4 ki L E ih EE n A ars 84 qg ue 3 5g usd JN A AID DING Bi si G gt 40 me TE x p Tr Ru Ev E 4 eu naases a gt m 2 16 2 GENERAL INFORMATION CABLE amp HARNESS ROUTING Front Brake Reservoi N w Front Stop i 95 hs 2 Throttle Cable Speedometer Cable Regulat t Rectifier Horn 2 17 SUPERS 50 2T Rear Stop Brake Rear Brake Cable Front Brake Fluid Tube 2 GENERAL INFORMATION SUPERS 50 2T Dimmer Switch i itch Turn Signal Switc Starter Switch Horn Switch Throttle Cable Ignition Switch Speedometer Cable Wire Harness Front Brake Fluid Tube Rear Brake Cable 2 18 2 GENERAL INFORMATION SUPERS 50 2T Fuel Cap Fuel Unit Oil Meter Fuel Tube Oil Filter Reed Valve Muffler Air Injection Control Valve Seat Cable Fuel Tank Air Cleaner Oil Tank Motor Connect wire Ignition Coil SparkPlug Oil Tube 2 19 2 GENERAL INFORMATION SUPERS 50 2T Battery Cable Battery Cable Oil Tube Spark Plug Cap Oil Control Cable Auto Bystarter wire A C G Connect wire Starter Relay Wire Harness Fuel
7. 13 14 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPERS 50 2T Remove the throttle seat screw Remove the throttle seat 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 STEM REMOVAL Remove the steering stem lock nut Steering Stem Lock Nut Wrench Lock Nut wrench Steering Stem Lock Nut Wrench 1345 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK Remove the top cone race e Be careful not to lose the steel balls 20 on top race and 15 on bottom race Clean the openings of frame covers with clean shop towels Remove the front fork BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race using a chisel gt Be carelul not to damage the steering stem and front fork Drive a new bottom cone race into place with a proper driver 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 SUPERS 50 2T Top Cone Race Bottom Cone Race Ball Race Remover Outer Driver Install the top and bottom steel balls 13 16 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPERS 50 2T Apply grease to the top an
8. eem 9 3 FINAL REDUCTION INSPECTION eene 9 3 FINAL REDUCTION ASSEMBLY dee ede dete pcr epe 9 6 9 0 SUPER8 50 2T 9 FINAL REDUCTION 9 1 9 FINAL REDUCTION 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 37 40 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 e Damaged transmission e Seized or burnt transmission Abnormal noise e Worn seized or chipped gears e Worn bearing Oil leaks e Oil level too high e Worn or damaged oil seal SUPER8 50 2T 9 2 9 FINAL REDUCTION SUPERS 50 2T FINAL REDUCTION DISAS SEMBLY Remove the rear wheel 214 3 Remove the left crankcase cover 28 4 Remove the clutch driven pulley 28 15 Drain the transmission gear oil into a clean container Remove the transmission case cover attaching bolts Remove the transmission case cover Remove the gasket and dowel pins Driver shift Remove the final gear and countershaft Final Shaft Driver shift Final Gear Countershaft FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage Countershaft
9. Ground clearance mm Starting system Compression pressure 11 8kg com 2 kg cm2 rpm Max output ps r min Speed limit No limit 2 8 6500 Open Automatic controlled Open Automatic controlled Pres ee Scaveng open Close Intake SUPER8 50 2T Fuel capacity ite 60 Piston dia l CDI electromagnetic 13 5 1 BTDC 2000 rpm Spark plug Spark plug gap mm 0 6 0 7 acl Carburetor Ignition timing F mark BR8HSA Battery capacity 12V6AH Power transmission Power to transmission gear Reduction ratio of power to transmission Clutch type Dry multi disc clutch Transmission gear operation Automatic centrifugal Transmission ratio 1 speed _ 2 reduction ratio Tire pressure kg em type Suspension Fro wheel type Shock absorber 2 GENERAL INFORMATION SUPERS 50 2T GENERAL INFORMATION ENGINE SERIAL 2 2 1 SERVICE PREGAUTIONS ER 2 2 SERVICE INFORMATION 2 10 TORQUE VALUES 15 rrt o e che e te 2 12 SPEGIAL TOOLS 2 13 FUBRICATION POINTS u repetitur aan cea eati ha eje deed a uu 2 15 WIRING DIAGRAM 2 16 GABLE amp HARNESS RO
10. Before performing the following test operate the turn signals to determine that the battery circuit is normal Check the fuel gauge needle for correct indication by moving the fuel unit float up and down Float Position Needle Position Ful Empty 16 INSTRUMENT SWITCHES LIGHTS SUPERS 50 2T INSTALLATION The installation sequence is the reverse of removal e Install the fuel unit at the connect position OIL METER INSPECTION Remove the met in box 212 4 Remove the frame body cover 212 4 Disconnect the oil meter wire connectors and remove the oil meter Keep the oil meter float at the lower position Measure the resistances between the wire terminals as and Q shown in the left figure Wire Terminals Resistance Green Red Black 460 Green Black Before removing the meter sure to drain the motor oil and do not allow sparks or flames near the working area 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 float at upper position Light OFF 4 5 1 0mm Green Red Black About 3000 Light ON Before performing the following test operate the turn signals to determine that the battery circuit is normal 16 3 16 INSTRUMENT SWITCHES LIGHTS SUPER8 50 2T Move the oil meter float up and down to see if the oil
11. Disconnect the oil inlet line from the oil pump Then disconnect the oil outlet line Before disconnecting the oil line clip the oil line to avoid oil flowing out and then plug the oil line after it is disconnected Remove the oil pump control cable plate bolt Remove the oil pump from the crankcase O ring OIL PUMP INSPECTION Remove the pump and inspect the following items e Weakened O ring e Damage to crankcase mating surface e Damage to pump body e Control lever operation e Oil leaks through oil seals e Worn or damaged pump pinion 0 Do not disassemble the oil pump which cannot be used after disassembly 4 3 ontrol Lever I Pinion 4 LUBRICATION SYSTEM OIL INSTALLATION Lubricate the O ring with grease engine oil before installation e Make sure that the oil pump is inserted into the crankcase e Apply molybdenum disulfide or grease to the pump pinion Install the oil pump onto the crankcase Install the oil pump control cable plate Connect the oil inlet line and oil outlet line properly Connect the oil pump control cable Bleed air from the oil pump SUPERS 50 2T Oil Inlet Line 4 4 4 LUBRICATION SYSTEM SUPERS 50 2T Intake Manifold OIL PUMP BLEEDING e Air in the oil lines will block oil flow and result in severe engine damage e Bleed air from the oil lines and oil pump whenever the oil lines or pump have been
12. Performance Test Remove the ignition coil oe Recta er Ignition Coil Inspect the ignition coil with an ignition coil tester gt Follow the ignition coil tester manufac turer s instructions 1 Turn the changeover switch to 12V and connect the ignition coil to the tester 2 Turn the power switch ON and check the spark from the watch window e Good Normal and continuous spark Faulty Weak or intermittent spark gt The test is performed at both conditions that the ignition coil is cold and hot A C GENERATOR Exciter Coil Pulser Coil Inspection This test is performed with the stator installed in the engine Remove the met in box 212 4 Disconnect the A C generator wire connector Measure the pulser coil resistance between the blue yellow wire and ground Resistance 20 C 100 1500 15 9 15 ELECTRICAL EQUIPMENT SUPERS 50 2T CDI UNIT INSPECTION Remove the front cover Disconnect the CDI coupler and remove the CDI unit CDI Unit CDI CIRCUIT INSPECTION Measure the resistance between the terminals Replace the CDI unit if the readings are not within the specifications in the table below Green Black Yellow Black Red e Due to the semiconductor in circuit it is necessary to use a specified tester for accurate testing Use of an improper tester in an improper range may give false readings e Use a Sanwa Electric Tester Electric Tester TH 5H
13. gauge Good Faulty Q Loose or disconnected connector Broken or shorted wire in fuel gauge 2 30 2 GENERAL INFORMATION SUPERS 50 2T STARTER MOTOR 1 Starter motor won t turn Inspection Adjustment Symptom Probable Cause Check operation of stop IER by r O Burned out fuse applying brake ET dead a 9 Faulty stop switc Stoplight comes on Stop lant does or disconnected Check battery connector circuit by operating gt Broken or shorted ignition turn signals switch wire Signals operate 5 Faulty or weak battery Check operation of properly remain on or don t starter relay by p depressing starter gt button Relay Relay does duni ud button C properly Faulty starter relay onnect starter Loose or disconnected 2 to _ connector x gt Starter motor turns Starter does not turn __ Faulty starter motor Faulty wire harness 2 Starter motor turns slowly or idles Ins
14. hee EOS Q Incorrect ignition timing r Flooded carburetor Q Throttle valve excessively Wait for 30 minutes and then remove the carbu retor auto choke circuit hose and blow the hose with mouth open 2 21 fire does not start gt Dry spark plug Wet spark plug gt Not clogged Clogged 9 Faulty auto bystarter 2 GENERAL INFORMATION SUPERS 50 2T ENGINE STOPS IMMEDIATELY AFTER IT STARTS Inspection Adjustment Symptom Probable Cause Check if fuel reaches carburetor by loosening drain Fuel reaches Fuel does not Clogged float valve I 9O Clogged charcoal canister carburetor reach carburetor Clogge d fuel filter Remove spark plug ty auto fuel valve and install it into spark plug cap to test spark by connecting it to engine ground Plug not fouled or Plug fouled or Fouled spark plug discolore discolojed Lo Incorrect heat range plug Remove spark plug and install it into spark plug cap to test spark by connecting it Fouled Par plug to engine ground n Me unit Weak or inter generator Good spark Faulty ignition coil SpA 9 Broken or shorted high tension wire Faulty ignition switch n
15. Q Broken auto bystarter wire Net cegged Clogged Faulty auto bystarter Connect auto bystarter wire to battery Wait for 5 minutes then connect a hose to fuel enriching circuit and Clogged Not clogged Faulty auto bystarter 2 26 2 GENERAL INFORMATION CLUTCH DRIVE AND DRIVEN PULLEYS Symptom Engine starts but motor cycle does not move SUPERS 50 2T Probable Cause Worn or slipping drive belt 0 Broken ramp plate Broken driven face spring Motorcycle creeps or engine starts but soon stops or seems to rush out Rear wheel rotates when engine idles Separated clutch lining 6 Damaged driven pulley shaft splines Damaged final gear Q Seized final gear Broken shoe spring Q Clutch outer and clutch weight stuck Engine lacks power at start of a grade poor slope performance Seized pivot O Worn or slipping drive belt 0 Worn weight rollers Engine lacks power at high speed Seized drive pulley bearings Weak driven face spring GO Worn or seized driven pulley bearings r Worn or slipping drive belt There is abnormal noise or smell while running Worn weight rollers Worn or seized driven pulley bearings r Q Oil or grease
16. Crankshaft bearing installation Pilot 20mm 00 20mm Crankshaft bearing installation Bearing installation _ outer driver handle p ineballitacs Bearing puller head 10mm puller head 10mm Front wheel Front wheel bearing removal removal Universal bearing puller Crankshaft bearing removal Bearing puller wheel bearing removal Pressure tester set oylnder compression gauge 2 14 2 GENERAL INFORMATION SUPERS 50 2T LUBRICATION POINTS ENGINE NO Lubrication Points Remarks 1 Crankcase sliding 8 movable WASO FC or APLTC 2 Cylindermovableparts 0 3 Transmission gear final SAES0R 4 Kick starter spindle bushing areae 0 Drive pulley movable parts 6 Starter pinion movable parts Grease Apply clean engine grease to cables movable parts not specified This will avoid abnormal noise and rise the durability of the motorcycle Engine Oil Throttle Cable Grease Front Rear Brake Lever Grease Seat Lock Grease Brake Cam Front Shock Absorber Lower Mount Grease Bushings Pivot Brake Cam Anchor Pin Engine Oil Rear Brake Cable Grease Rear Wheel Bearing Grease Main Stand Pivot 2 15 Speedometer Gear 2 GENERAL INFORMATION SUPERS 50 2T PEOPLE S 50 WIRING DIAGRAM 5 4 wz m m x m s 499 6
17. Resin Washer 9 3 9 FINAL REDUCTION Inspect the final gear and final shaft for wear damage or seizure Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage Inspect the 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 remove the transmission case cover except for necessary replacement When replacing the drive shaft also replace the bearing and oil seal SUPER8 50 2T Drive Shaft Bearing Countershaft Bearing Drive Shaft Bearing Oil Seal 9 FINAL REDUCTION SUPERS 50 2T Drive Shaft Bearing BEARING REPLACEMENT Transmission Case Cover Remove the transmission case cover bearings using the bearing remover Remove the final shaft oil seal Bearing Remover Set Bearing Outer Driver Handle 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 left crankcase bearings using the bearing remover Bearing Remover Set 12mm 9 FINAL REDUCTION SUPERSSOZT Drive 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 crankcas
18. broken or shorted wire Between A C generator and CDI unit Between CDI unit and ignition coil Between CDI unit and ignition switch Between ignition coil and spark plug e Faulty ignition switch e Faulty ignition coil e Faulty CDI unit e Faulty A C generator STARTING SYSTEM Starter motor won t turn e Fuse burned out e Weak battery e Faulty ignition switch e Faulty starter switch e Faulty front or rear stop switch e Faulty starter relay e Poorly connected broken or shorted wire e Faulty starter motor SUPER8 50 2T Engine starts but turns poorly e Ignition primary circuit Faulty ignition coil Poorly connected wire or connector e Ignition secondary circuit Faulty ignition coil Faulty spark plug Poorly insulated plug cap e Improper ignition timing Battery voltage too low 6V max Faulty CDI unit Lack of power e Weak battery e Loose wire or connection e Foreign matter stuck in starter motor or pinion Starter motor rotates but engine does not start e Faulty starter pinion e Starter motor rotates reversely e Faulty starter clutch e Weak battery 15 2 15 ELECTRICAL EQUIPMENT SUPERS 50 2T CHARGING SYSTEM Dimmer Switch Ignition Switch Resistor BATTERY 12V4AH 15 3 15 ELECTRICAL EQUIPMENT SUPERS 50 2T BATTERY BATTERY REMOVAL Remove the battery cover Disconnect the battery cables First disconnect the battery negative ca
19. e Bleed air from the oil pump after installation e The oil tube clip at the oil tank side must be locked from inside of the oil tube joint 4 6 5 ENGINE REMOVAL INSTALLATION 50 2T ENGINE REMOVAL INSTALLATION SERVICE INFORMATION nnn ER etiem ehe ER ERROR E REP coni 5 1 ENGINE REMOVAL EO EG bn exe eb RE 5 2 ENGINE INSTALLATION rir nr ER Rcx dein enacted 5 4 5 ENGINE REMOVAL INSTALLATION SUPER8 50 2T SERVICE INFORMATION GENERAL INSTRUCTIONS e A floor jack or other adjustable support is required to support and maneuver the engine Be careful not to damage the motorcycle body cables and wires during engine removal e Use shop towels to protect the motorcycle body during engine removal e Parts requiring engine removal for servicing Crankcase Crankshaft TORQUE VALUES Engine mounting bolt 4 5 5 5kg m Rear shock absorber lower mount bolt 2 4 3 0kg m Engine hanger bracket bolt 3 5 4 5kg m 5 ENGINE REMOVAL INSTALLATION SUPERS 50 2T ENGINE REMOVAL Remove the frame body cover 212 5 Remove the five bolts attaching the air cleaner case Loosen the band between the air cleaner and carburetor to remove the air cleaner case Remove the carburetor cap Carburetor Cap Air Cleaner Case Disconnect the auto bystarter generator starter motor wire connectors Disconnect the oil pump control
20. e In this table Needle swings then returns indicates that there is a charging current applied to a condenser The needle will then remain at unless the Violet Black Black Blue Violet Red condenser is discharged Blue Yellow Use the x KO range for the Sanwa Tester Use the x 1000 range for the Tester N 15 10 15 ELECTRICAL EQUIPMENT SUPERS 50 2T STARTING SYSTEM Starter Button Starter Relay Starter Motor FR STOP SW START SW COMB SW inte Pre BATTERY 229 12V4AH O R FUSE CASE B L FUSE G A B FUSE RR STOP START MOTOR 15 ELECTRICAL EQUIPMENT SUPERS 50 2T Starter Relay STARTER RELAY INSPECTION Remove the foot floor cover Disconnect the starter relay coupler and then remove the starter relay Connect the starter relay D terminal to the 12V 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 MOTOR REMOVAL Disconnect the starter motor cable Remove the two bolts attaching the starter motor and remove the starter motor The installation sequence is the reverse of removal Starter Motor 15 ELECTRICAL EQUIPMENT SUPERS 50 2T STARTER MOTOR INSPECTION Connect a battery
21. its main stand on level ground The gear oil level shall be at the oil check bolt hole If the oil level is low add the specified oil to the proper level Specified Gear Oil SAE 90 Install and tighten the oil check bolt Torque 1 0 1 5kg m Start the engine and check for oil leaks Oil Check Bolt 3 7 3 INSPECTION ADJUSTMENT ELECTRICAL EQUIPMENT IGNITION APPARATUS Spark Plug Remove the frame center cover Remove the spark plug cap and spark plug Check the spark plug for wear fouling and carbon deposits Remove the fouling and carbon deposits with a spark plug cleaner or wire brush Specified Spark Plug BR8HSA NGK SF10JA Spark Plug Gap 0 6 0 7mm Ignition Apparatus The CDI ignition timing is not adjust able If the timing is incorrect check the CDI unit ignition coil and A C generator and replace any faulty parts Remove the right side rail gt 12 4 Remove the A C generator fan cover 27 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 running at the specified rpm the ignition timing is correct if the F mark on the flywheel aligns with the index mark on the crankcase within 1 5 Ignition Timing 13 5 1 BTDC 2000rpm SUPERS 50 2T Gap Wear and Fouling Deposits 0 6 0 7mm Washer Damage Index Mark 3 INSPECTION A
22. s abnormal noise Operation Oil check bolt hole at lower hole edge transmis sion case m Spark plug condition E Plug 0 6 0 7mm Battery Terminal connection connection Loose connection and Wires damage Electrical Equipment 3 INSPECTION ADJUSTMENT SUPERS 50 2T Frequency Inspection amp Maintenance B ist Every 6 Every 12 Judgment Standards Remarks rior month months months Performance and abnormal noise Conditions at low and high Body speeds Exhaust cleaner manash IR Oil level indicator Oil quality and quantity Indicator light comes on E when oil is insufficient Oil leakage AEE a Oil level Checkoilfiterforclogging O Fuelleakage Carburetor throttle valve and Fuel auto bystarter o 100224020 _ Fueltube replacement lansa vinor Lights amp Winker Winking action dirt and damage Buzzer amp 2 Steering Lock o fof Rearview Mirror amp R iti Rearview Reflector earview mirror position Mirror Reflector amp Comer Operation lol C Murmer Exhaust mutter pertormance O Body amp Frame Loosenessanddamage of 0 Engine Check if the abnormal conditions occur again uwan olol T Remove carbon deposits
23. 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER SUPER8sO2T _ SERVICE INFORMATION SPECIFICATIONS Standard mm Service Limit mm Rear wheel rim runout Rear brake drum 1 0 Rear brake lining thickness Rear shock absorber spring free length 235 7 218 7 TORQUE VALUES Rear axle nut 11 0 13 0kg m Rear 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 wobbling e Bent rim e Faulty tire e Axle not tightened properly Soft rear shock absorber e Weak shock absorber spring Poor brake performance e Brake not adjusted properly e Contaminated brake linings e Worn brake linings e Worn brake shoes at cam contacting area e Worn brake cam e Improper engagement between brake arm and wear indicator plate 14 2 14 REAR WHEEL REAR BRAKE REAR _ SHOCK ABSORBER SUPERBS02T Rear Axle Nut REAR WHEEL REMOVAL Remove the two exhaust muffler joint lock nuts Remove the two exhaust muffler lock bolts Remove 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 Rear Axle Nut INSTALLATION Install the rear wheel and apply SAE30 engine oil to the axle threads Then tighten the rear axle nut
24. BRAKE PERFORMANCE Symptom Index mark on brake panel aligns with wear indicator arrow Brake squeaks Brake performance is Expanding _ poor Brake Hydraulic Brake Q Foreign matter on brake linings _ Rough brake drum contacting area Sluggish or elongated brake cables 9 Brake shoes improperly contact brake drum Water and mud in brake system Oil or grease on brake linings Faulty brake master cylinder Q Faulty brake caliper Oil or grease on brake disk Deformed brake disk O Leaking brake fluid tube 2 28 2 GENERAL INFORMATION SUPERS 50 2T OIL METER 1 Motor oil indicator light does not come on when there is no motor oil Ignition switch ON Inspection Adjustment Symptom Probable Cause Check battery circuit Sands t Burned out fuse Signals operate Signals dim remain _ Fauity ignition Switch properly don t operate Loose or disconnected Connect indicator Broken wis harness light bulb to battery gt for bulb inspection Bulb lights Bulb does not lightt_ Burned out bulb Check connectors for proper operation Loose wire connector Good Faulty Broken wire harness Incorrectly connected Remove oil meter and wire check operation of indicator
25. Flywheel puller Universal holder 7 2 T A C GENERATOR SUPERS 5027 _ Fan A C GENERATOR REMOVAL an Cover Remove 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 Universal Holder 7 3 7 SUPERS 50 2T Lock Nut Wrench Remove the A C generator flywheel using the flywheel puller Remove the A C generator wire connector M oO A C Generator Wire Remove the two pulser coil bolts and pulser Stator Pulser Coil coil from the right crankcase wm Remove the pulser coil wire clamp from the right crankcase Remove the two bolts attaching the A C generator stator Be careful not to damage the disconected wire A C GENERATOR INSTALLATION Install the A C generator stator and pulser coil wire clamp onto the right crankcase and then install the pulser coil Wire Clamp 7 4 7 A C GENERATOR SUPERS 5027 l A C Generator Wire Install the A C generator and pulser coil bolts Connect the A C generator wire connector SZ Clean the taper hole in the flywheel off any burrs and dirt Install the woodruff 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
26. Install 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 3 0 4 0kg m Fill the brake reservoir with recommended brake fluid and bleed air from the brake system FRONT SHOCK ABSORBER REMOVAL Remove the front cover gt 2 Remove the front wheel Remove the front shock absorber upper mount bolts Loosen the lower mount bolts to remove the front shock absorbers 13 1 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPERS 50 2T INSPECTION Inspect the following items and replace if necessary eFront shock absorber tube bending or damage eWeak front shock absorber spring D eDamper and damper rod bending eOil seal damage or wear X N e 0 9 INSTALLATION Mount Boot Install the front shock absorbers onto the steering stem Install and tighten the front shock absorber upper mount bolts Tighten the lower mount bolts Align the upper mount bolt hole with the groove on the front fork Front shock absorbers are installed at the same altitude Install the front wheel STEERING HANDLEBAR REMOVAL Remove the handlebar covers 2 Remove the rear brake lever holder bolt to remove the holder Remove the front brake master cylinder holder bolts to remove the brake master cylinder
27. SUPERS8 50 2T ASSEMBLY DRAWING 12 1 12 FRAMECOVERS SERVICE INFORMATION e When removing frame covers use care not to pull them by force because the cover joint claws may be damaged Items Related for Removal e Handlebar front cover Headlight wire e Front cover e Handlebar rear cover Speedometer cable and instrument light wire connectors etc e Frame body cover Met in box rear carrier rear fender e Floor board frame body cover e Front tool box Front cover battery floor board 12 2 12 5 SUPERS 50 2T FRAME COVERS REMOVAL REAR CARRIER Remove the met in box First remove 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 attaching the rear protective cover Remove the rear protective cover 12 3 12 FRAMECOVERS Remove the two screws on the bottom of the center 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 Side Cover Battery Wire Disconnect the battery wire Remove the battery Battery 12 4 12 5 SUPERS 50 2T Bolts Remove the floor mat Remove the
28. center cover 212 3 Remove the screws and bolts attaching the front right and left side covers Remove the four bolts attaching the floor foot Remove the floor foot The installation sequence is the reverse of removal LEG SHIELD LOW REMOVAL Remove the met in box Remove the body cover Remove 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 removal FRONT UPPER COVER REMOVAL Remove the eight screws on the back of the front upper cover Remove the bolt and two adjusting screws on the front of the front upper cover Disconnect the signal light wire connector Remove the front upper cover The installation sequence is the reverse of removal Screws 12 5 12 FRAME 5 Remove four bolts attaching left right rear step Remove the rear step WINDSHIELD REMOVAL Remove the 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 attaching the handlebar rear cover Remove the handlebar rear cover The installation sequence is the reverse of removal Rear Step SUPER8 50 2T 12 5 SUPERS 50 2T Remove the four nuts attaching the handlebar cover Re
29. distance between the left crankcase oil seal and crankcase surface is about 1 0mm Oil Seal H Install and tighten the crankcase attaching bolts After assembly check the crankshaft for smooth operation 10 8 11 CARBURETOR 5 8 50 2T CARBURETOR SERVICE INFORMA FION sits ieri iue Ii rper edie 11 2 TROUBLDESHOQGTING teorico 11 2 THROTTLE VALVE DISASSEMBLY ettet eee 11 3 THROTTLE VALVE INSTALLATION terre P Pret Re e tts 11 4 CARBURETOR REMOVAL t nee 11 5 AUTO BYSTARTER 11 6 FLOAT GHAMBER utor E rre ee o iret boo 11 8 FLOAT LEVEL INSPECTION tp ice doa 11 10 CARBURETOR INSTALLATION tine 11 11 AIR SCREW ADJUSTMENT n ical 11 11 HEED VAEVE soo uQ won ns edt e KM eg ERR 11 12 FUEL TANIS ie pa g su na cr bata 11 13 11 CARBURETOR SUPERS 50 2T Oy ES B e z 9 Cm gt NP AT T S KW 2 C j 11 CARBURETOR SUPERS 50 2T SERVICE INFORMATION GENERAL INSTRUCTIONS When working with gasoline keep away from sparks and flames Note the locations of O rings when disassembling and replace them with new ones during asse
30. engine and open the fuse box Disconnect the wire lead from the fuse terminal Connect an ammeter between the wire lead and fuse terminal as shown Connect the battery positive terminal to the voltmeter positive probe and battery negative terminal to the voltmeter negative probe Start the engine gradually increase engine speed to test the output 6000 Charging Limit Voltage 14 5 0 5V 8000rpm If the limit voltage is not within the specified range check the regulator rectifier A C GENERATOR CHARGING COIL INSPECTION gt Inspect with the engine installed Remove the met in box 212 4 Disconnect the A C generator connector Measure the resistances between the charging coil terminals pink and lighting coil terminals yellow Resistances Charging coil Lighting coil Refer to 7 3 for A C generator removal 15 5 15 ELECTRICAL EQUIPMENT SUPERS 50 2T RESISTOR INSPECTION Remove the frame front cover 212 3 Measure the resistance between the resistor with ground Resistances Resistor 9 9 12 00 gt Faulty resistor is the cause of faulty operation of the auto bystarter REGULATOR RECTIFIER INSPECTION Remove the front cover gt 12 3 Disconnect the regulator rectifier wire coupler and remove the bolt to remove the regulator rectifier Resister Measure the resistances between the terminals Replace the regulator rectifier if the readings are not
31. excessive play CRANKSHAFT INSTALLATION Wash the crankshaft in cleaning solvent and then check for cracks or other faults e After check apply clean engine oil to all moving and sliding parts e Remove all gasket material from the crankcase mating surfaces Dress any roughness or irregularities with an oil stone 10 5 10 CRANKCASE CRANKSHAFT __SUPER5027_ Bearing Outer Driver Handle Drive a new crankshaft bearing into the right crankcase Bearing Outer Driver 37x40mm Bearing Driver Pilot 17mm Bearing Outer Driver Handle A Drive new crankshaft bearing into the left crankcase x BAN 4 Bearing Outer Driver 42x47mm Pilot 20mm Crankcase Assembly Tool DN r Install the crankshaft into the left crankcase e Apply KYMCO ULTRA motor oil or molybdenum disulfide to the crankshaft bearings and connecting rod big end e Apply grease to the lip of the oil seal and then install it 10 CRANKCASE CRANKSHAFT SUPERS 50 2T Dowel Pins 117 4 CRANKCASE ASSEMBLY Install the dowel pins and a new gasket to the crankcase mating surface Assemble the crankcase halves A jJ i Bad Crankcase Assembly Collar The distance between the right crankcase oil Oil Seal seal and crankcase surface is about 12 5 0 5 mm gt When installing the oil seal be careful to press it with even force 10 7 10 CRANKCASE CRANKSHAFT SUPER8502T _ The
32. fouled drive belt Worn drive belt 9 Weak driven face spring Worn or seized driven pulley bearings STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Q Symptom Steering is heavy Probable Cause Front and rear tire pressures are normal Steering stem nut too tight Front or rear wheel is wobbling Q Broken steering steel balls Q Excessive wheel bearing play Bent rim 2 27 Steering handlebar pulls to one side Loose axle nut Misaligned front and rear wheels Q Bent front fork 2 GENERAL INFORMATION POOR SUSPENSION PERFORMANCE SUPERS 50 2T Probable Cause Front and rear tire pressures are normal r Weak shock spring Excessive load G Shock damper oil leaking r Bent fork tube or shock rod Q Fork slider and tube binding Fork tube and spring binding Q Fork slider and tube binding Probable Cause Adjust brake according to standards Worn brake linings Worn brake cam contacting area on brake shoes Worn brake cam Worn brake drum Worn brake linings Symptom Suspension is too soft Suspension is too hard Suspension is noisy Z POOR
33. needle clip amp Needle Clip Check the jet needle and throttle valve for wear or damage Jet Needle e Throttle Valve Rubber Seal Carburetor Cap THROTTLE VALVE INSTALLATION 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 Connect the throttle cable to the throttle valve Throttle Cable 11 CARBURETOR SUPER8 50 2T Groove Install the throttle valve by aligning the groove in the throttle valve with the throttle stop screw Tighten the carburetor cap After installation perform the following adjustments and inspections e Throttle cable free play gt 3 12 Idle speed adjustment 23 11 Install the met in box Throttle Cable Fuel T CARBURETOR REMOVAL uel Tube Remove the met in box 212 4 Remove the air cleaner by removing the air cleaner band screw and attaching bolts Disconnect the fuel tube Loosen the drain bolt to drain fuel from the carburetor Disconnect the auto bystarter wire connector Remove the two carburetor lock nuts 11 5 11 CARBURETOR SUPER 50 2T Remove the carburetor Nut AUTO BYSTARTER AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals Resistance 5Q 10 minutes minimum after stopping the engine If the resistance exceeds 5Q replace the auto bystarter with a new
34. on Others combustion chamber breather hole and exhaust muffler 3 3 3 INSPECTION ADJUSTMENT SUPERS 50 2T Master Cylinder BRAKE SYSTEM Inspect the brake fluid level Recommend brake fluid DOT4 Normal limit BRAKE LEVER Rear 10 20mm Measure the front and rear brake lever free plays Free Play Rear 10 20mm Rear A Marks If the free plays do not fall within the limits turn the right and left adjusting nuts for adjustment Adjusting Nuts 3 INSPECTION ADJUSTMENT SUPERS 50 2T Rear A Marks BRAKE DRUM SHOE Shoe Wear Replace the brake shoes if the arrow on the brake arm aligns with reference mark on the brake panel when the brake is fully applied Brake Drum Wear Damage Check the brake drum appearance for damage Check if the brake lining wear is within the specified service limit Check the brake operation for abnormal noise and brake drum inside for wear or damage Adjusting Nuts 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 Inspection Stand the motorcycle wheels off the ground and check if the brake disk run out is within the specified service limit Brake Disk BRAKE FLUID LEVEL INSPECTION Brake Master Cylinder Fluid Level Inspection Turn the steering handlebar uprigh
35. removed or there is air in the oil lines Oil Fump OIL INLET LINE OIL PUMP BLEEDING Fill the oil tank with recommended oil Place a shop towel around the oil pump Disconnect the oil inlet line from the oil pump and clip it Fill the oil pump with oil by squirting clean oil through the joint About 3cc Fill the oil line with oil and connect it to the oil pump Bleed air from the oil inlet line first then bleed air from the oil outlet line OIL OUTLET LINE BLEEDING 1 Disconnect the oil outlet line and bend it into U shape Force air out of 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 1 there is no oil flowing out within 1 minute bleed air from the oil inlet line and oil pump Oil Outlet Line e Never the engine closed area e Do not increase the engine speed at Oil Tube will 4 5 4 LUBRICATION SYSTEM SUPERS 50 2T Oil Meter OIL TANK OIL TANK REMOVAL Remove the met in box 312 5 Remove the frame body cover 512 5 Remove the rear carrier 212 5 Remove the oil meter connector Remove 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 Wire Connector e Connect the oil line properly
36. schedule is based upon average riding conditions Machines subjected to serve use or ridden in unusually dusty areas require more frequent servicing Frequency Inspection amp Maintenance Item ist Every6 Every 12 Judgment Standards Remarks rior month months months Suspension Check steering stem Check steering stem Front fork Check front fork pivot for B looseness and abnormal noise Front rear brake lever free play rake Lever Brake lever operation Brake performance Free play 10 20mm Indicator type Standard Rear 110 mm Service Limits Rear 111 mm 1 175 2 25 ider kg cm kg cm Brake drum wear and damage Lu 61619 9 100 80 110 70 1 12 16 16 3 INSPECTION ADJUSTMENT SUPERS 50 2T Inspection amp Maintenance Item m Every 6 Every 12 Judgment Standards Remarks m onth months months Groove Depth Tire groove and mmmz of elo Imbedded objects gravel etc Torque Values Front axle nut Axle nut looseness 5 0 7 0kg m Rear axle nut 11 0 13 0kg m Rim runout at rim end Check wheel rim rim Front Axial 2 0mm edge and spoke plate Radial 2 0mm for damage 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 Suspen Connecting parts loose sion arm ness and arm damage Assembly parts loose
37. the instrument set correctly B When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions B Be careful not to drop any parts B When rust is found on a terminal remove the rust with sand paper or equivalent R Rust before connecting Tug Cr 2 8 2 GENERAL INFORMATION SUPERS 50 2T B Symbols The following symbols represent the servicing methods and cautions included in this service manual Apply engine to the specified points Use B designated engine oil for lubrication Engine Oil A Apply grease for lubrication Grease C Use special tool Special Caution V Warning 2 9 2 GENERAL INFORMATION SUPERS 50 2T SERVICE INFORMATION ERE Cyinderheadwapage 0 1 02 00 Cylinderto piston clearance on 0 10 0 25 Connecting rod small end I D CARBURETOR n notch Id Th e fr Jet needle clip 1st notch 2 10 2 GENERAL INFORMATION SUPERS 50 2T SUPER8 50 2T SUPER8 50 2T 5 7 4 0 235 7 Standard mm Service Limit mm 2020 Rear shock absorber spring free length 218 7 0 2 ELECTRICAL EQUIPMENT SUPERS8 50 2T Capacity 12V6AH Voltage 13 0 13 2V Battery Charging Standard 0 4A 5H current 4A 0 5H Spark plug BR8HSA Spark plug gap 0 6 0 7mm Primary coil 0 153 0 1870
38. within the specifications in the table below e Due to the semiconductor in circuit it is necessary to use a specified tester for accurate testing Use of an improper tester in an improper range may give false readings e Use a Sanwa Electric Tester 07208 0020000 or Kowa Electric Tester TH 5H The proper range for testing is listed below Regulator Reclifior Black TH 5H lt 2 Yellow Green 15 6 15 ELECTRICAL EQUIPMENT SUPERS 50 2T IGNITION SYSTEM Ignition Coil Ignition Switch Spark Plug 4 av Pd a 4 x A C Generator Exciter Coil Ignition Switch 32205 L 15 ELECTRICAL EQUIPMENT SUPERS 50 2T IGNITION COIL INSPECTION Continuity Test gt This test is to inspect the continuity of ignition coil Remove the met in box 212 4 Measure the resistance between the ignition coil primary coil terminals Resistance 20 C 0 153 0 1870 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 14 Figure Figure Measure the secondary coil resistance between the ignition coil terminal and the primary coil terminal as Figure B shown Resistance 20 C without plug cap 7 9KQ 15 8 15 ELECTRICAL EQUIPMENT SUPERS 50 2T
39. x not squeeze wires against the weld or its clamp x Q O m After clamping check each harness to make sure that it is not interfering with any gt toot moving or sliding parts N m When fixing the wire harnesses do not no conati make it contact the parts which will generate high heat pn B Route wire harnesses to avoid sharp edges or corners Avoid the projected ends of bolts and screws B Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws 2 6 2 GENERAL INFORMATION m Route harnesses so they are neither pulled tight nor have excessive slack Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner m When rubber protecting cover is used to protect the wire harnesses it shall be installed securely m Do not break the sheath of wire B f a wire or harness is with a broken sheath repair by wrapping it with protective tape or replace it B When installing other parts do not press or squeeze the wires 2 7 SUPERS 50 2T 1 2 GENERAL INFORMATION SUPERS 50 2T After routing check that the wire harnesses are not twisted or kinked Q Wire harnesses routed along with handlebar should not be pulled tight have excessive slack or interfere with adjacent or surrounding parts all steering positions Do you understand the Instrument Is
40. 1 SPECIFICATIONS SUPERS 50 2T TABLE OF CONTENTS 1 5252 0 an aora 1 GENERAL INFORMATIONN J 2 INSPECTIONVADJUSTMENTI L 3 LUBRICATION SYSTEMN 4 ENGINE REMOVAL INSTALLATION 5 CYLINDER HEAD CYLINDER PISTONN 6 A G GENERATOR iniu ua sauce CELOS 7 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY 8 9 CRANKCASE CRANKSHAFT 10 11 FRAME COVERS uA dun mucua aaah ada Ra nu nomas ku 12 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK 13 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER 14 ELECTRICAL EQUIPMENT 55 15 INSTRUMENT SWITCHES LIGHTS 16 EXHAUST EMISSION CONTROL SYSTELMN 17 1 SPECIFICATIONS SPECIFICATIONS m Net weight kg Gross Rear whee ee
41. 10mm flywheel flange nut Torque 3 5 4 0kg m Start the engine and check the ignition timing 3 8 Install other removed parts in the reserve order of removal 7 5 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY SUPER 5027 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY 2 ode deze ates qii tudine 8 2 TROUBLESHOOTING br 8 2 KICKSTARTER P 8 3 DRIVE aoa abies 8 7 DRIVE PULLEY Merkel de ir cuf 8 9 STARTER ONE WAY CLUTCH DRIVE GEAR n ee teretes 8 11 GEUTOH DBIVEN PULLEY D ton 8 14 8 STARTER DRIVE PULLEY CLUTCHIDRIVENPULLEY 2 S C 3 5 4 0kg m k 7 e 8 STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY 5 8 50 2T SERVICE INFORMATION GENERAL INSTRUCTIONS e Avoid getting grease and oil on the drive belt and pulley faces Service Limit mm 7 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 Universal holder Clutch spring compressor Lock nut socket wrench 32mm Bearing outer driver 37x40mm Bearing driver pilot 17m
42. 6g grease Specified grease 230 C Heat resistant grease 8 15 8 STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY SUPERS 50 27 Bearing Driver Pilot Drive in a new needle bearing into the driven face with the mark facing up Outer Driver 24x26mm Driven Pulley Oil Seal 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 O rings Guide Roller Pin Install the seal collar Seal Collar 8 16 8 STARTER DRIVE PULLEY CLUTCHIDRIVENPULLEY SUPERS S027 _ Set the driven pulley driven face spring and clutch assembly onto the clutch spring compressor Compress the tool and install the 28mm drive plate nut Tighten the 28mm nut to the specified torque Torque 5 0 6 0kg m Clutch Driven Pulley CLUTCH DRIVEN PULLEY INSTALLATION Install the drive belt on the clutch driven pulley and then install the clutch driven pulley onto the drive shaft Install the clutch outer Hold the clutch outer with the universal holder Install and tighten the 10mm clutch outer nut Torque 3 5 4 5kg m Install the left crankcase cover 58 7 Clutch Outer 8 17 9 FINALREDUCTION SUPERS 5027 FINAL REDUCTION SERVICE INFORMATION ninth nta Renee Sn RR ERE RM RAE a 9 2 TROUBLESHOOTING e dae ER XU 9 2 FINAL REDUCTION DISASSEMBLY
43. BRAKE FRONT SHOCK ABSORBER FRONT FORK HYDRAULIC BRAKE FRONT BRAKE BRAKE FLUID REPLACEMENT AIR BLEEDING Check the brake fluid level on level ground e When operating the brake lever the brake reservoir cap must be tightened securely to avoid splash of brake fluid e When servicing the brake system use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid BRAKE FLUID BLEEDING In order to avoid spilling brake fluid connect a transparent hose to the bleed valve Spilled brake fluid on brake pads or brake disk reduces stopping power Clean the brake pads and brake disk with a high performance brake Fully apply the brake lever and then loosen the brake caliper bleed valve to drain the brake fluid until there is no air bubbles in the brake fluid Then tighten the bleed valve Repeat these steps until the brake system is free of air BRAKE FLUID REFILLING Add DOT 3 brake fluid to the brake reservoir e When bleeding be careful not to allow air in the brake reservoir flowing into the brake system e Never use dirty or unspecified brake fluid or mix different brake fluids be cause it will damage the brake system Make sure to bleed air from the brake system BRAKE PAD DISK REPLACEMENT brake pads must replaced as setto ensure the balance of the brake Remove the two bolts attaching the brake caliper Remove the brake calipe
44. DJUSTMENT SUPERS 50 2T Throttle Stop Screw ENGINE BODY At High and Low Speeds engine must warm for accurate idle speed adjustment Adjust the idle speed to the specified range by turning the throttle stop screw and air screw Idle Speed 1850 100rpm Air Cleaner Remove air cleaner cover by removing the five bolts cleaner cover screws 3 4 a gt Screws Remove the air cleaner element Air Cleaner 3 INSPECTION ADJUSTMENT SUPERS 50 2T Wash the air cleaner element in detergent oil squeeze out and allow to dry Never use gasoline or organic vaporable oil with acid or alkali for washing After washing soak the element in clean engine oil SAE 10W 30 and squeeze out excess oil Reinstall the element Saueeze out Wash Squeeze Soak in oil out and dry Cylinder Compression Warm up the engine before compression test Remove the spark plug and insert a compression gauge Open the throttle valve fully and push the starter button for 7 8 seconds to test the compression Compression 11 8kg cm If the compression is low check for the following e Leaking cylinder head gasket e Worn piston cylinder If the compression is high it indicates that carbon deposits have accumulated on the combustion chamber and the piston head LUBRICATION SYSTEM Filter Cleaning Disconnect the oil tube at the oi
45. Inspect the kick starter spindle bushing for wear or damage Spindle Bushing Plastic Bushing Friction Spring Check the kick starter driven gear for wear or damage Check the friction spring for wear or damage Kick Starter Driven Gear 8 STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY SUPERS 50 2T Inspect the kick starter spindle and driven Kick Starter Spindle Forcing Part gear forcing parts for wear or damage a Kick Starter Driven Gear Forcing Part KICK STARTER INSTALLATION Friction Spring Install the kick starter spindle bushing and return spring onto the left crankcase cover If the hooks of the return spring can not be installed properly use a screw driver to press them into their locations respectively Properly install the kick starter driven gear Friction Spring and friction spring as the figure shown Kick Starter Driven Gear 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVENPULLEY SUPER 9027 First install the washer and then the circlip onto the kick starter spindle Install the kick lever Washer Circlip Dowel Pins LEFT CRANKCASE COVER INSTALLATION First install the dowel pins and then the seal o9 rubber Seal Rubber Left Crankcase Cover Install the left crankcase cover and tighten the ten bolts diagonally Connect the drive belt cooling air tube and install the circlip For drum brake note the location of the bra
46. Note the locations of tubes for proper installation e Replace any damaged tube with a new one e Make sure to tighten the connector of each tube securely TOOLS e Vacuum pump SPECIFICATIONS Air injection cut off valve actuating pressure 250mm Hg 30 liter min Reed valve stopper clearance 4 6mm 17 2 17 EXHAUST EMISSION CONTROL SYSTEM SUPER8 50 2T ECONDARY AIR CLEANER AIR Secondary Air Cleaner A I C V INJECTION CONTROL VALVE A I C V Y REMOVAL Remove the seat 22 4 Remove the body cover Disconnect the secondary air cleaner A 1 C V connecting tube INSPECTION Air Inlet Tube Remove two screws on the air cleaner air injection control valve Air Outlet Tube Replace new one when the filter elements obstruct considerable dirt INSTALLATION The installation sequence is the reverse of removal The secondary air cleaner must be Air Inlet Tube assembled and installed properly to avoid dust entering the air cleaner e When installing be careful not to bend or twist the tubes and check for proper installation e he tube length is very important to its performance use the tube of same specification for replacement 17 3 17 EXHAUST EMISSION CONTROL SYSTEM SUPER8 50 2T Reed Valve Cover Bolt REED VALVE REMOVAL Disconnect the secondary air inlet tube connector Remove the reed valve cover three bolts Secondary Air Inlet Tube Clip Remove the three bo
47. RE ERA 13 13 STEERING HANDLEBAR 5 05 I ta ira rx a KE nae 13 14 STEERING STEM c 13 15 13 0 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPERS 50 2T 6 0kg m 13 1 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPERS 50 2T SERVICE INFORMATION GENERAL INSTRUCTIONS e Remove the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down e During servicing keep oil or grease off the brake drum and brake linings e Contaminated brake disk or brake pads reduce stopping power Clean the contaminated brake disk with high performance brake degreaser and replace the brake pads e Do not use brake fluid for cleaning e Bleed air from the brake system if the brake system is removed or the brake is soft e Do not allow any foreign matters to enter the brake system when filling it with brake fluid e Brake fluid will damage painted surfaces and plastic parts When servicing the brake system use shop towels to cover and protect rubber plastic parts and coated surfaces Wipe off any spilled brake fluid with a clean shop towel e Inspect the brake system before riding SPECIFICATIONS Standard mm Axle shaft runout Front wheel rim runout Front brake lining thickness Front shock absorber spring free length Brake disk thickness Bra
48. Tank Cap 2 20 2 GENERAL INFORMATION TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment Check if fuel reaches carburetor by loosening drain screw Symptom SUPERS 50 2T Probable Cause Empty fuel tank Fuel reaches carburetor Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Fuel does not reach carburetor r 9 Clogged float valve 1 1 9O Clogged charcoal canister r Clogged fuel filter Spark jumps Weak or no spark Faulty auto fuel valve r Q Faulty spark plug Fouled spar plug Faulty CDI unit Faulty A C generator Test cylinder compression xir or shorted ignition en or shorted exciter coi Faulty ignition switch O Burned worn cylinder Normal compression Low or no compression Faulty reed valve Blown cylinder head gasket Start engine by follow ing normal starting procedure Leaking crankcase Faulty crankcase oil seal mO Incorrectly adjusted idle Engine does not Engine fires but spee J Air leaking through intake Remove spark plug and inspect again
49. Torque values Rear axle nut 11 0 13 0kg m 14 3 14 WHEEL REAR SHOCK ABSORBER SUPERssO2T REAR BRAKE Remove the rear wheel 214 3 Inspect the rear brake drum Measure the rear brake drum 1 0 Service Limit 95 5mm replace if over BRAKE LINING INSPECTION Measure the brake lining thickness Service Limit 2 0mm replace if below gt Keep oil or grease off the brake linings REAR BRAKE DISASSEMBLY Brake Arm Brake Shoes Remove the rear brake adjusting nut and disconnect the rear brake cable Remove the rear brake shoes Adjusting Nut 14 4 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER Remove the brake cam bolt to remove the brake arm wear indicator plate and felt seal Remove the brake arm REAR BRAKE ASSEMBLY Apply grease to the anchor pin and brake shoe moving parts Apply grease to the brake cam and install it Apply engine oil to the felt seal and install it to the brake cam Install the wear indicator plate Align the wide tooth of the wear indicator plate with the wide groove on the brake cam Install the brake arm onto the brake cam gt Align the punch mark on the brake arm with the scribed line on the brake cam Install and tighten the brake arm bolt Install the brake arm return spring Install the brake shoes 14 5 SUPER8 50 2T Brake Arm Brake Cam Grease Wear Indicator Plate Br
50. UTIN G 2 17 TROUBLESHOOTING 2 ette Rhet et me tr p 2 21 2 GENERAL INFORMATION SUPERS 50 2T ENGINE SERIAL NUMBER IDENTIFICATION Location of Engine Serial Number 2 1 2 GENERAL INFORMATION SERVICE PRECAUTIONS m Make sure to install new gaskets O rings circlips cotter pins etc when reassembling m When tightening bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally Use genuine parts and lubricants B When servicing the motorcycle be sure to use special tools for removal and installation m After disassembly clean removed parts Lubricate sliding surfaces with engine oil before reassembly SUPERS 50 2T 2 2 2 GENERAL INFORMATION SUPERS 50 2T m Apply or add designated greases lubricants to the specified lubrication points After reassembly check all parts for proper tightening and operation m When two persons work together pay attention to the mutual working safety B Disconnect the battery negative terminal before operation B When using a spanner or other tools make fe sure not to damage the motorcycle surface m After operation check all connecting points fasteners and lines for proper connection and installation B When connecting the battery the positive terminal must be con
51. VALUES Cylinder head bolt 1 5 1 7kg m Exhaust muffler joint lock nut 1 8 2 2 Exhaust muffler lock bolt 3 0 3 6kg m Spark plug 1 1 1 7kg m Qe TROUBLESHOOTING Compression too low hard starting or poor performance at low speed Leaking cylinder head gasket Loose spark plug e Worn stuck or broken piston and piston rings e Worn or damaged cylinder and piston Compression too high overheating or knocking e Excessive carbon build up in cylinder head or on piston head Abnormal noisy piston e Worn cylinder and piston e Worn piston pin or piston pin hole e Worn connecting rod small end bearing Abnormal noisy piston rings e Worn stuck or broken piston rings e Worn or damaged cylinder 6 2 6 CYLINDER HEAD CYLINDER PISTON SUPERS 50 2T CYLINDER HEAD Mg sp REMOVAL Remove the rear carrier Remove the frame body cover 212 5 Remove the spark plug cap Remove the three bolts attaching the fan Fan Cover Engine Hood cover to remove the fan cover Remove the two joint lock nuts on the front of the exhaust muffler and then remove 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 When installing the exhaust muffler first tighten the two nuts on the front and then tighten the two bolts Bolts Bolt Remove the spark plug Remove the cylinder head bolts and the Cylinder
52. across the starter motor Starter Motor and check for its operation Battery Terminal 1 Do not turn the starter motor for a long time 2 This inspection should be done with a fully charged battery 16 INSTRUMENT SWITCHES LIGHTS SUPERS 50 2T SERVICE INFORBRMNATION iieri iue Ei 16 1 TROUBLESHOOTING aka nad a 16 1 FUEL UNIT rero Re dus wha q kaya yapu 16 2 QIE METER S un Set 16 3 SIA GBS as easyer dregs avers T 16 4 STOP SWITCH INSPECTION HORN m a tein 16 6 FRONT TURN SIGNAL LIGHT REPLACEMENT eem 16 7 INSTBUMENT HEADLIGH tbc te tcd 16 8 16 0 16 INSTRUMENT SWITCHES LIGHTS SERVICE INFORMATION GENERAL INSTRUCTIONS SUPERS 50 2T e Wires should be connected to other wires of the same color Couplers must be connected to other couplers of the same color e All plastic plugs have locking tabs that must be released before disconnecting and must be aligned when reconnecting e After installation of each switch a continuity check must be performed TROUBLESHOOTING Lights do not come on when ignition switch is e Burned bulb e Faulty switch e Broken or shorted wire e Fuse burned ou
53. ake Arm 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER SUPER 50 27 Install the brake arm pin Brake Cable Brake Arm Connect the brake cable and install the adjusting nut Install the rear wheel 214 3 Adjust the rear brake lever free play 53 4 Adjusting Nut REAR SHOCK ABSORBER REMOVAL Upper Mount Bolt Remove the front cover 12 6 Remove the met in box 212 5 Remove the air cleaner case 25 2 Remove the rear shock absorber upper and lower mount bolts to remove the rear shock absorber Lower Mount Bolt INSTALLATION Rear Shock Absorber Install the rear shock absorber Install the rear shock absorber upper mount bolt and then install the lower mount bolt Torque Upper Mount Bolt 3 5 4 5kg m Lower Mount Bolt 2 4 3 0kg m Install the frame body cover 212 5 15 ELECTRICAL EQUIPMENT SUPERS 50 2T SERVICE INFORMATION TROUBLESHOOTING moderados tds 15 1 GHARGING SYSTEM rias eere coh o D pe aon di deis 15 3 BATTERY aset P Eee de po 15 4 IGNITION SYSTEM ae bed codi pipe ie toned ca denda 15 7 STARTING SYSTEM a ran Pr t ase 15 11 15 0 15 ELECTRICAL EQUIPMENT SUPERS 50 2T SERVICE INFORMATION GENERAL INSTRUCTIONS It is not necessary to check the battery electrolyte or fill with distilled water e Remove the battery from the mo
54. allation e Throttle cable Oil pump control cable gt 3 11 e Rear brake cable 23 5 Oil pump bleeding 23 11 Engine Hanger Bushings SUPERS 50 2T Stopper Rubbers 6 CYLINDER HEAD CYLINDER PISTON SUPER8 50 2T CYLINDER HEAD CYLINDER PISTON SERVICE INFORMA FION ii rgo e rerit S erbe etes TROUBEESHOOTING 3 5 A eae donata CYLINDER BEAD a qa item safe idet Sese GYEINDER PIS a 6 CYLINDER HEAD CYLINDER PISTON SUPERS 50 2T Torque 1 1 1 7kg m cold 6 1 6 CYLINDER HEAD CYLINDER PISTON SUPERS 50 2T SERVICE INFORMATION GENERAL INSTRUCTIONS e The cylinder head cylinder and piston can be serviced with the engine installed in the frame e Before disassembly clean the engine to prevent dust from entering the engine e Remove all gasket material from the mating surfaces e Do not use a driver to pry between the cylinder and cylinder head cylinder and crankcase e Do not damage the cylinder inside and the piston surface e After disassembly clean the removed parts before inspection When assembling apply the specified engine oil to movable parts SPECIFICATIONS Standard mm Service Limit mm Cytinderheadwarpage owo Piston O D 5mm from bottom of piston skirt Cyinderto piston clearance ow Piston ring end gap top second Cylinder bore TORQUE
55. alve Reed Valve Filter secondary air Prevent exhaust muffler noise and backfiring at sudden deceleration Control the secondary air inlet to reduce CO Function It filters the fresh air drawn for re burning to prevent dirt or dust from affecting the operation of the air injection cut off valve The air injection cut off valve usually opens to lead air into the exhaust muffler in which air is re burned to reduce CO When the throttle valve closes suddenly the air injection cut off valve is actuated by vacuum to close and cut off secondary air in order to prevent exhaust muffler backfiring due to air in the exhaust system When the motorcycle speed is less than 50km per hour the reed valve operates to draw secondary air into the exhaust system for re combustion 17 1 17 EXHAUST EMISSION CONTROL SYSTEM SUPER8 50 2T TROUBLESHOOTING High CO at idle speed 1 Damaged or clogged reed valve 2 Damaged or clogged air injection cut off valve 3 Clogged air cleaner Backfiring at sudden deceleration 1 Damaged reed valve malfunction 2 Faulty air injection cut off valve unable to close 3 Carburetor incorrectly adjusted 4 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 e During operation be careful to avoid scalding caused by the exhaust muffler e
56. alve and gasket Intake Manifold Reeds Reed Stopper INSPECTION Check the reed valve for damaged or weak reeds Check the reed valve seat for cracks damage or clearance between the seat and reed Replace the valve if necessary Do not disassemble bend the reed stopper To do so can cause loss of engine power and engine damage If any of the stopper reed or valve seat is faulty replace them as a unit Reed Valve Seat INSTALLATION Install the reed valve in the reverse order of removal e Install a new gasket with the gasket indentation aligned with the reed valve e After installation check for intake air leaks 11 12 11 CARBURETOR FUEL REMOVAL Remove the met in box 12 4 Remove the frame body cover 212 5 Remove the rear carrier gt 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 fuel unit 216 2 Replace the fuel unit if necessary ASSEMBLY 11 13 SUPERS 50 2T Bolts Fuel Unit Fuel Tank Fuel Tank Holder Fuel Tube 12 FRAMECOVERS 5 SERVICE INFORMATION tnter a 12 2 FRAME COVERS 12 3 EXHAUST MUFFLER REMOVAL trad ke ce eren 12 8 12 0 12 5
57. ark as the old one Measure the piston O D at a point 5mm from the bottom of the piston skirt Service Limit 38 90mm replace if below Measure the piston to cylinder clearance 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 piston pin clearance Service Limit 0 03mm replace if over 6 8 6 CYLINDER HEAD CYLINDER PISTON SUPERS 50 2T PISTON RING INSPECTION Measure each piston ring end gap Service Limits Top Second 0 40mm replace if over Set each piston ring squarely into the cylinder using the piston and measure the end gap Small End 1 0 Measurement CONNECTING ROD SMALL END INSPECTION Install the piston pin and bearing in the connecting rod small end and check for excessive play Measure the connecting road small end 1 0 Service Limit 17 03mm replace if over PISTON CYLINDER INSTALLATION First install the expander in the second ring Top Ring 1st 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 force After installation check and make sure that each ring is flush with the piston at several points around the ring Second Ring A ring that will not compress means that the Expander ring groove has carbon deposits in it a
58. attaching the instruments to the handlebar rear cover Remove the instruments Bolts HEADLIGHT REMOVAL BULB REPLACEMENT Remove the handlebar rear cover 22 Remove the bulb sockets and bulbs e The model adopts krypton gas bulb When installing do not directly touch the bulb glass with fingers e Use bulbs of the same specifications for replacement The installation sequence is the reverse of removal Bulb Sockets 17 EXHAUST EMISSION CONTROL SYSTEM SUPERS 50 2T EXHAUST EMISSION CONTROL SYSTEM SCHEMATIC DRAWING eiui 17 1 EXHAUST EMISSION CONTROL SYSTEM 2 17 1 TROUBLESHOOTING 17 2 SERVICE INFORMATION nu asa kiasa Ca Dee oret 17 2 SECONDARY AIR CLEANER edere neo p bue eene Sad eb can 17 3 AIR INJECTION CUT OFF 1 17 3 REED VALVE dea seti Do tene s uqu a aee n du nM ecu dA 17 4 17 0 17 EXHAUST EMISSION CONTROL SYSTEM SCHEMATIC DRAWING SUPERS 50 2T zx Fresh air Catalytic converter EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system adopted in this model utilizes the reed valve to draw secondary air into the exhaust system for re combustion by means of exhaust pulsation so as to minimize the exhaust emission FUNCTION Secondary Air Cleaner Air Injection Cut off V
59. bearing cavities with grease Drive in the left bearing Install the distance collar Drive in the right bearing e Do not allow the bearings to tilt while driving them in e Drive in the bearing squarely with the sealed end facing out Driver handle A 13 5 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPERS 50 2T Apply grease to a new dust seal lip and install the dust seal Install the side collar INSTALLATION Apply grease to the brake panel dust seal lip Apply grease to the speedometer gear engaging and sliding parts Install the brake panel by aligning the speedometer retaining pawls with the hub cutouts If not aligned the retaining pawl will be deformed when the axle nut is tightened After installing the axle turn the wheel to make sure that the soeedometer drive shaft rotates freely 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 Torque 5 0 7 0kg m Install the front brake cable and rotate the front tire to check the speedometer if be performed Axle Nut Connect the speedometer cable Speedometer Cable 13 6 SUPER8 50 2T 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK HYDRAULIC BRAKE DRAWING 13 7 13 STEERING HANDLEBAR FRONT WHEEL FRONT
60. ble and then the positive cable Remove the battery The installation sequence is the reverse of removal BATTERY CHARGING OPEN CIRCUIT VOLTAGE INSPECTION Remove the battery cover and disconnect the battery cables Measure the voltage between the battery terminals Fully charged 13 0V 13 2V Undercharged 12 3V max gt Battery charging inspection must be performed with an electric tester CHARGING METHOD Connect the charger positive cable to the battery positive cable Connect the charger negative cable to the battery negative cable e Keep flames and sparks away charging battery e Turn power ON OFF at the charger not at the battery terminals to prevent sparks near the battery e Charge the battery according to the Black current specified on the battery surface 12222 2 222727702 Charging current Standard 0 4 ED ae Quick 4A Charging time Standard 5 hours Quick 0 5 HOUR After charging Open circuit voltage 12 8V min e Quick charging should only be done in an emergency e During quick charging the battery temperature should not exceed 45 C e Measure the voltage 30 minutes after the battery is charged 15 4 15 ELECTRICAL EQUIPMENT SUPERS 50 2T PERFORMANCE TEST Warm up the engine Remove the floor mat and front tool box cover gt Use a fully charged battery to check the charging system output Stop the
61. bystarter wire to battery Wait for 5 minutes then connect a hose to fuel enriching circuit and then blow the hose with mouth Clogged Not Clogged Faulty auto bystarter 2 23 2 GENERAL INFORMATION ENGINE LACKS POWER Inspection Adjustment Start engine and accelerate lightly for observation Symptom Engine speed increases Check ignition timing using a timing light Engine speed does not increase sufficiently SUPER8 50 2T Probable Cause Clogged air cleaner r 9 Clogged fuel filter Correct timing Incorrect timing Clogged exhaust muffler Faulty auto bystarter Q Faulty charcoal canister Faulty CDI unit Testcylinder compression using a compression gauge Norm Abnormal compression Check carburetor for clogging Not Clogged Clogged Remove spark plug and 1 Plug not fouled or Plug fouled or Faulty A C generator Worn cylinder and piston rings Blown cylinder head gasket 9 Faulty reed valve O Clogged carburetor jets _ Fouled spark plug Check if engine overheats
62. cable from the pump bogy Disconnect the oil inlet line from the oil pump Remove the spark plug cap After the oil inlet line is disconnected plug the oil line opening to prevent oil from flowing out Oil Pump Control Cable Spark Plug Cap 5 2 5 ENGINE REMOVAL INSTALLATION SUPER8 50 2T Rear Shock Absorber Lower Mount Bolt Remove the rear brake adjusting nut and disconnect the brake cable from the crankcase Remove the rear brake cable clamp and rear brake cable Remove the rear shock absorber lower mount bolt Remove the right and 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 Mounting Nuts ENGINE HANGER BRACKET REMOVAL Remove the engine hanger bracket bolt and engine hanger bracket The installation sequence is the reserve of removal Torque 3 5 4 5kg m Engine Hanger Bracket Bolt 5 ENGINE REMOVAL INSTALLATION ENGINE HANGER BRACKET INSPECTION Inspect the stopper rubbers and bushings for damage and replace with new ones if necessary ENGINE INSTALLATION Install the engine in the reverse order of removal gt Cables and wires should be routed properly 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 after inst
63. chet align with the teeth of the crankshaft 8 KICK STARTER DRIVE PULLEY CLUTCHIDRIVENPULLEY SUPERS S027 _ DRIVE PULLEY REMOVAL Hold the drive pulley with the holder and remove the 12mm drive face nut Remove the starting ratchet 12mm washer and drive pulley face TENET 1 WWW 12mm Drive Face Nut Drive Pulley Collar MOVABLE DRIVE FACE DISASSEMBLY Remove the movable drive face and drive pulley collar from the crankshaft j Movable Drive Face Ramp Plate Remove the ramp plate 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY SUPERS 5027 _ Weight Roller MOVABLE DRIVE FACE INSPECTION Remove the weight rollers Check each weight roller for wear or damage Measure each roller O D Service Limit 12 4mm replace if below Measure the movable drive face bushing assembly 1 0 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 sliding surface Service Limit 19 9mm replace if below DRIVE PULLEY INSTALLATION O a E HVS TACE Install the drive pulley collar and movable drive face onto the crankshaft 8 10 8 STARTER DRIVE PULLEY CLUTCHIDRIVENPULLEY Install the drive belt on the crankshaft Drive Pulley Face Install the drive face starting ratchet and washer then tighten the 12mm drive face nut To
64. cylinder head Remove the two exhaust muffler joint lock nuts and two exhaust muffler lock bolts Remove the exhaust muffler Remove the cylinder Remove the cylinder gasket gt Do not pry between the cylinder and crankcase or strike the fins PISTON REMOVAL Remove the piston pin clip to remove the piston pin and piston e Do not damage or scratch the piston eDo not apply side force to the connecting rod when removing the piston pin e Place clean shop towels in the crankcase to keep the piston pin clip from falling into the crankcase Spread each piston ring and remove by lifting it up at a point just opposite the gap Remove the expander Cylinder Piston Pin Piston 6 CYLINDER HEAD CYLINDER PISTON SUPERS 50 2T CYLINDER PISTON INSPECTION Check the cylinder and piston for wear or damage Clean carbon deposits from the exhaust port area gt Be careful not to damage the cylinder inside wall Measure the cylinder bore at three levels of 3 A B and C in both X and Y directions Avoid the port area the maximum figure measured to determine the cylinder bore Service Limit 39 05mm replace if over Inspect the top of the cylinder for warpage Service Limit 0 10mm replace if over 6 CYLINDER HEAD CYLINDER PISTON SUPERS 50 2T A Mark The cylinder has an A mark or no mark on it When replacing the cylinder with a new one use a cylinder having the same m
65. d bottom ball races and install 20 steel balls on the top ball race and 15 steel balls on the bottom ball race Apply grease to the ball races and install the front fork Apply grease to the top cone race and install 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 sk Check that the steering stem rotates freely without vertical play Install the steering stem lock nut and tighten it while holding the top cone race Torque 7 0 8 0kg m Install the front wheel 212 15 2 Cone Race Top Cone Race Lock Nut Wrench HANDLEBAR INSTALLATION Install the handlebar onto the steering stem tube and then install and tighten the bolt Torque 4 5kg m Install the front wheel 212 6 Install the brake levers 212 15 Install the handlebar covers 13 17 14 REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER SUPER8sO2T _ REAR WHEEL REAR BRAKE REAR SHOCK ABSORBER 14 2 TROUBLESHOOTING es estate p I t te i etre 14 2 REAR WHEEL pisri 14 3 BEAR BRAKE lt lt tuin soie dei utin 14 4 REAR SHOCK ABSORBER ned bee tdt 14 6 14 0 14 REAR WHEEL REAR BRAKE REAR _ SHOCK ABSORBER SUPERBS02T 11 0kg m 14 1
66. e Final Shaft 9 FINAL REDUCTION SUPERS 50 2T Dowel Pins position Install the countershaft and gear into the left crankcase Install the washer onto 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 removed parts in the reverse order of removal 9 7 9 FINALREDUCTION SUPERS 5027 Oil Check Bolt Hole Filler After installation fill the transmission case en with the specified oil 2 e Place motorcycle its main stand on level ground e Check the sealing washer for wear or damage m 22 Specified Gear SAE90 S E Capacity at disassembly 0 12 liter 4m uA at change 0 09 liter Install tighten the oil check bolt Torque 1 0 1 5kg m Start the engine and check for leaks Drain Bolt Check the oil level from the oil check bolt hole and add the specified oil to the proper level if the oil level is low 9 8 10 CRANKCASE CRANKSHAFT SUPER8502T _ CRANKCASE CRANKSHAFT SERVICE INFORMATION 10 2 TROUBLESHOOTING LA 10 2 CRANKCASE SEPARATION 10 3 CRANKSHAFT REMOVAL 10 3 CRANKSHAFT ANSPEGTIDN
67. e the handlebar front cover 212 3 Disconnect the front and rear stop switch wire couplers Check for continuity between the wire terminals when the front rear brake lever is applied 16 INSTRUMENT SWITCHES LIGHTS SUPERS 50 2T Horn Terminal HORN INSPECTION Remove the frame front cover 212 3 Disconnect the horn wire couplers The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals FRONT TURN SIGNAL LIGHT REPLACEMENT Remove three screws attaching the turn signal light set and remove the light set T Replace with new set of the same specifications Turn Signal Light Set TAILLIGHT STOPLIGHT REAR TURN SIGNAL LIGHT BULB REPLACEMENT Taillight Base Removal Remove the rear protective cover Remove the seat Remove the body cover Remove the taillight base The installation sequence is the reverse of remove Taillight Base 16 7 16 INSTRUMENT SWITCHES LIGHTS SUPER8 50 2T Bulb Socket INSTRUMENTS BULB REPLACEMENT Remove the handlebar rear cover 52 Remove the bulb socket and replace the bulb The installation sequence is the reverse of removal INSTRUMENTS REPLACEMENT Remove the handlebar rear cover 22 Disconnect the right and left handlebar switches wire couplers Disconnect the speedometer cable Remove the instrument bulb sockets Disconnect the two fuel gauge wires Remove the instrument wire clamp screw Remove the three screws
68. fouled spark plug KC oer Weak or inter r 9 Faulty A C generator 19905045 mittent spark M Faulty ignition coil Broken or shorted high Remove auto tension wire bystarter connecting Faulty ignition switch wire and check if bypass fuel line is clogged Broken auto bystarter wire Not clogged Clogged EE Connect auto bystarter Faulty auto bystarter wire to battery Wait for 5 minutes then connect a hose to fuel enriching circuit and then blow the hose with mouth Clogged Not clogged 2 25 2 GENERAL INFORMATION SUPERS 50 2T POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Loose A C G stator G Faulty A C generator Check auto fuel valve for fuel supply Empty fuel tank Fuel flows freely Fuel flow Clogged fuel tube or filter restricted Clogged charcoal canister Check carburetor jets for clogging g Not clogged Clogged 0O Clean and unclog Remove auto bystarter connecting wire and check if gt bypass fuel line is clogged
69. head Bolts cylinder head gt Loosen the bolts diagonally in 2 or 3 times Remove the cylinder head gasket Spark Plug Cylinder Head 6 3 6 CYLINDER HEAD CYLINDER PISTON SUPERS 50 2T Combustion Chamber COMBUSTION CHAMBER DECABONIZING Remove the carbon deposits from the combustion chamber Avoid damaging the combustion cham ber wall and cylinder mating surface Mating Surface CYLINDER HEAD INSPECTION Check the cylinder head for warpage with a straight edge and feeler gauge Service Limit 0 10mm replace if over Cylinder head Gasket CYLINDER HEAD INSTALLATION Install the cylinder head on the cylinder properly gt Be careful not to damage the mating surfaces Install a new cylinder head gasket onto the cylinder 6 CYLINDER HEAD CYLINDER PISTON SUPERS 50 2T Cylinder head Bolts Cylinder Head Bolts Installation Install and tighten the cylinder head bolts diagonally in 2 or 3 times Torque 1 5 1 7kg m Install the spark plug Torque 1 1 1 7kg m Cylinder Head Spark Plug Engine Hood Installation Install the engine hood 6 3 Install the spark plug cap 6 3 Perform the following inspections after installation e Compression test e Abnormal engine noise e Cylinder air leaks 6 CYLINDER HEAD CYLINDER PISTON SUPERS 50 2T CYLINDER PISTON CYLINDER REMOVAL Remove the met in box and seat Remove the frame body cover Remove the
70. hen remove the O rings and oil seal from the driven pulley O rings Guide Roller Pin CLUTCH DRIVEN PULLEY INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit 107 5mm replace if below 8 13 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY SUPER8SO2T Check the clutch shoes for wear or damage Measure the clutch lining thickness Service Limit 2 0mm replace if 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 below Check the movable driven face for wear or damage Measure the movable driven face I D Service Limit 34 06mm replace if below Check the guide roller pins for stepped wear 8 14 8 STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY SUPFR65S02T DRIVEN PULLEY FACE BEARING Inner Bearing REPLACEMENT Check the needle bearings in the driven face and replace them if they have excessive play damage or abnormal noise Drive the inner bearing out of the driven pulley face Snap Ring Remove the snap ring and drive the outer bearing out of the driven face Outer Bearing Bearing Outer Driver 37x40mm Drive a new outer bearing into the driven face with the sealed end facing up Seat the snap ring in its groove all bearing cavities with 5 0 5
71. indicator light will go out and come on 50 60 4 70 20 40 k Y 3 er If the oil indicator light does not light check for burned bulb loose wire or connector After correction check again according to the method mentioned above SWITCHES IGNITION SWITCH INSPECTION Remove the front cover 212 3 Disconnect the ignition switch wire couplers and check for continuity between the wire terminals Color Red BlackWhite Green Black Symbol tock msnm mo IGNITION SWITCH REPLACEMENT Remove the front cover 212 3 Disconnect the ignition switch wire couplers Remove the two mounting bolts and remove the ignition switch The installation sequence is the reverse of removal 16 INSTRUMENT SWITCHES LIGHTS SUPERS 50 2T DIMMER SWITCH INSPECTION Dimmer Switch Check for continuity between wire terminals TURN SIGNAL SWITCH INSPECTION Check for continuity between the wire terminals Turn Signal Switch 16 5 16 INSTRUMENT SWITCHES LIGHTS SUPER8 50 2T STARTER SWITCH INSPECTION Check for continuity between wire terminals Push the starter button when measuring HORN SWITCH INSPECTION Check for continuity between wire terminals Push the horn button when measuring Light Green Brown Blue Symbol BAT FRE 0 PUSH Horn SwitCh Stop Switch Wire STOP SWITCH INSPECTION Remov
72. kcase assembly tool Bearing outer driver 37x40mm Bearing driver pilot 17mm TROUBLESHOOTING Abnormal engine noise e Excessive crank journal bearing play e Excessive crankpin bearing play e Excessive transmission bearing play 10 2 10 CRANKCASE CRANKSHAFT SUPERS 50 2T CRANKCASE SEPARATION Remove the crankcase attaching bolts Attach the 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 left crankcase gt When removing the crankshaft do it slowly and gently 10 3 10 CRANKCASE CRANKSHAFT SUPER8502T _ Remove the remaining bearing on the crankshaft side using the universal bearing puller When separating the crankcase the oil seals must be removed Replace the oil seals with new ones Universal Bearing Puller CRANKSHAFT INSPECTION 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 0 04mm replace if over 10 4 10 CRANKCASE CRANKSHAFT SUPERS 50 2T Measure the crankshaft runout a ee 0 150mm 0 100mm replace if over replace if over Check the crankshaft bearings for excessive play The bearings must be replaced if they are noisy or have
73. ke cable clamp and install the rear brake cable in place with the clamp 8 STARTER DRIVE PULLEY CLUTCHIDRIVENPULLEY SUPERS S027 _ DRIVE BELT Remove the left crankcase cover INSPECTION Check the drive belt for cracks separation lt abnormal excessive wear Measure the drive belt width Service Limit 16 5mm replace if below Use specified genuine parts for replacement Clutch Outer Clutch Outer Nut 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 Universal Holder Ratchet Drive Face Hold the drive pulley with the holder and remove the 12mm drive face nut Remove the starting ratchet Remove the drive pulley face Drive Face Nut 8 7 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY SUPER 90 27 Clutch Driven Pulley Remove the drive belt from the clutch driven pulley Drive Belt Drive Belt DRIVE BELT INSTALLATION Turn the driven pulley clockwise and lift it up to expand the drive belt groove and then install 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 When installing the drive face nut make sure that the tooth spaces of the drive pulley face and starting rat
74. ke disk runout Brake disk runout TORQUE VALUES Steering stem bolt 4 0 5 0kg m Brake caliper bleed valve 0 6kg m Steering stem lock nut 7 0 8 0kg m Brake fluid tube bolt 3 0 4 0kg m Steering top cone race 0 5 1 3kg m Brake pad pin bolt 1 5 2 0kg m Front shock absorber bolt 2 0 2 5kg m Brake caliper bolt 2 9 3 5kg m Front axle nut 5 0 7 0kg m Brake master cylinder bolt 1 0 1 4kg m 13 2 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPERSG 50 2T SPECIAL TOOLS Lock nut wrench Driver handle A Outer driver 28x30mm Pilot 10mm Ball race remover Outer driver 37x40mm Pliers close Bearing remover Bearing remover head 10mm TROUBLESHOOTING Hard steering heavy Front wheel wobbling e Excessively tightened steering stem top Bent rim cone race Excessive wheel bearing play e Broken steering balls e Bent spoke plate e Insufficient tire pressure e Faulty tire Steers to one side or does not track straight Improperly tightened axle nut e Uneven front shock absorbers Soft front shock absorber e Bent front fork e Weak shock springs e Bent front axle or uneven tire e Insufficient damper oil Poor brake performance Front shock absorber noise e Incorrectly adjusted brake e Slider bending e Worn brake linings e Loose fork fasteners e Contaminated brake lining surface e Lack of lubrication e Worn brake shoes at cam contacting area e Worn brake drum e Poorly connected brake arm Poo
75. l pump side and allow oil to drain into a clean container Remove the tube clip at the oil tank side and disconnect the oil tube Remove the oil filter Oil Filter 3 INSPECTION ADJUSTMENT SUPERS 50 2T Clean the oil filter screen with compressed air Install the oil filter in the reverse order of removal and fill the oil tank with specified oil up to the proper level Bleed air from the oil pump and oil lines e Connect the oil tubes securely e Install the tube clip at the oil tank side and also install the clip to the lower oil tube that goes to the oil pump e Check for oil leaks Oil Pump Condition Adjust oil pump control cable after the Lock Nut Control Lever Aligning Mark throttle grip free play is adjusted ia Open the throttle valve fully and check that the index mark on the pump body aligns with the aligning mark on the oil pump control lever Reference tip alignment within 1mm of index mark on open side is acceptable Start and idle the engine then slowly open the throttle to increase engine rpm and check the operation of the oil pump control lever If adjustment is necessary adjust the oil pump control cable by loosening the control cable lock nut and turning the adjusting nut Adjusting Nut Pump Body Index Mark After adjustment tighten the lock nut Reference tip alignment within 1mm of index mark on open side is acceptable However the aligning mark on the control lever mus
76. les to enter the carburetor Check the carburetor insulator and O ring for wear or damage Install the carburetor and insulator onto the intake manifold and tighten the two lock nuts Connect the fuel tube and auto bystarter wire connector Route the auto bystarter wire correctly and properly Insulator Install the carburetor cap 211 4 Install the air cleaner onto the carburetor and tighten the band screw Fuel Tube Carburetor Cap Install the met in box 512 4 7 AIR SCREW ADJUSTMENT Remove the met in box 512 4 gt Warm up the engine before air screw adjustment Turn the air screw clockwise until it seats lightly and back it to the specification given Air Screw Opening turns Start the engine and turn the air screw in or out slowly to obtain the highest engine speed Air Cleaner Do not force the air screw against its seat to prevent damage Turn the throttle stop screw to obtain the specified idle speed Idle Speed 1950 100rpm Slightly increase the engine speed and make sure that the engine does not miss or run erratic If the adjustment of the air screw within the range of turn makes no difference to the engine performance check other related Throttle Stop Screw items 11 11 11 CARBURETOR SUPER 50 2T REED VALVE REMOVAL Remove the rear carrier Remove the frame body cover Remove the four intake manifold bolts and gasket Remove the reed v
77. light by moving float Faultv float Faulty floa Good Fauny L Broken or shorted wire in Float up Light off meter Float down Light on aS 2 Motor oil is sufficient but the indicator light remains on Ignition switch ON Inspection Adjustment Symptom Probable Cause Check connectors for proper connection O Loose A disconnected Faul connector ogee any Broken wire harness Remove oil meter and Incorrectly connected check operation of wire indicator light by moving float gt Float up Light off Good Faulty Faulty float id li Q Broken or shorted wire in Float down Light on metor o Damaged oil tank Q Foreign matters in oil tank 2 29 2 GENERAL INFORMATION SUPERS 50 2T FUEL GAUGE 1 Pointer does not register correctly Ignition switch ON Inspection Adjustment Check battery circuit Symptom Probable Cause by operating turn E signals Burned out fuse Weak or dead battery Signals operate Signals dim remain Faulty ignition switch I properly on or don t
78. lts attaching the reed valve cover and the reed valve Reed Valve INSPECTION 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 4 6mm INSTALLATION Install the reed valve in the reverse order of removal e When installing be careful not to bend or twist the tubes and check for proper installation 17 4 Reed Stopper
79. m One way clutch puller Outer driver 24x26mm TROUBLESHOOTING Poor performance at high speed or Engine starts but motorcycle won t move lack of power e Worn drive belt e Worn drive belt e Broken ramp plate e Weak driven face spring e Worn or damaged clutch lining e Worn weight roller e Faulty driven face Engine stalls or motorcycle creeps e Broken clutch weight spring 8 2 8 STARTER DRIVE PULLEY CLUTCHIDRIVENPULLEY SUPERes02T _ KICK STARTER LEFT CRANKCASE COVER REMOVAL Remove the nine left crankcase cover bolts left crankcase cover and dowel pins Inspect the left crankcase cover seal rubber for damage or deterioration Left Crankcase Cover Kick Starter Spindle KICK STARTER SPINDLE REMOVAL Remove the kick lever from the kick starter spindle Remove the and washer from the kick starter spindle Washer Circlip Friction Spring Slightly rotate the kick starter spindle to remove the kick starter driven gear together with the friction spring Kick Starter Driven Gear 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY SUPERS 50 2T Return Spring Remove the kick starter spindle and return spring from the left crankcase cover Remove the kick starter spindle bushing Kick Starter Spindle zz Return Spring Spindle KICK STARTER SPINDLE INSPECTION Inspect the kick starter spindle and gear for wear or damage Inspect the return spring for weakness or damage
80. mbly All cables fuel lines and wires must be routed and secured at correct locations Bleed air from the oil lines whenever they are disconnected SPECIFICATIONS Venturi dia Identification number Float level Main jet Slow jet 35 Air screw opening Throttle grip free play SPECIAL TOOL Float level gauge TROUBLESHOOTING Engine does not start Lean mixture e No fuel in tank e Clogged fuel jets e Faulty float valve e Too much fuel getting to cylinder e Clogged fuel cap vent e Float level too low e Clogged fuel filter e Clogged fuel filter e Clogged air cleaner e Clogged air cleaner e Bent kinked or restricted fuel line Engine idles roughly stalls or runs poorly Rich mixture e Incorrect idle speed e Clogged air cleaner e Faulty float valve e Ignition malfunction e Intake air leaks e Float level too high e Compression too low e Fuel contaminated e Clogged air jets e Incorrectly adjusted air screw Faulty reed valve e Incorrect float level e Clogged fuel jets 11 2 11 CARBURETOR 50 2T THROTTLE VALVE DIS ASSEMBLY Remove the rear carrier 212 5 Remove the met in box 212 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 cap and rubber seal Rubber Seal Carburetor Cap 11 3 11 CARBURETOR SUPERS 50 2T Remove the jet needle by removing the
81. mbly inspect the Ist 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 e During assembly the main piston spring must be installed as a unit without exchange e When assembling the piston soak the cups in brake fluid for a while e Install the cups with the cup lips facing the correct direction Install the main piston spring and snap ring Install the diaphragm Install the brake lever 13 10 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPERS 50 2T Place the brake master cylinder on the handlebar and install the holder with the up mark facing up Also align the punch mark with the holder joint seam First tighten the upper bolt and then tighten the lower bolt Torque 1 0 1 4kg m Install the brake fluid tube with the attaching bolt and two sealing 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 the method stated in page 12 8 BRAKE CALIPER FRONT REMOVAL Remove the brake caliper and brake pad springs 512 9 Place a clean container under the brake caliper and disconnect the brake fluid pipe from the caliper Do not spill brake fluid on any coated surfaces DISASSEMBLY Remo
82. move 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 Under Cowl Screws F RONT FENDER AND UNDER COWL REMOVAL Remove the two on the under cowl Remove the under cowl 12 7 12 FRAMECOVERS Lid Leg Shield Clip Body Remove the L R side bolts attaching the front fender and front fender EXHAUST MUFFLER REMOVAL Remove two lock 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 reverse of removal Torque Exhaust muffler joint lock nut 2 2kg m Exhaust muffler lock bolt 3 3kg m 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPERS 50 2T FRONT WHEEL FRONT BRAKE FRONT SUSPENSION SERVICE INFORMATION dre dira Ene RR Plc Rs OG n E ER RE usasqa 13 2 TROUBLESHOOTINQ senatu drix E cx Ie 13 3 FRONT WHEEL nicer edis genii cis ia ci bU d eur RD XR I QUK DR wayu 13 4 HYDRAULIC BRAKE nnne nnn nnn 13 7 HYDRAULIC BRAKE ka asas s 13 8 FRONT SHOCK lt 522220222520220 1929 00 cina n ER ENG Sin UE EE O
83. nd should be cleaned 6 9 6 CYLINDER HEAD CYLINDER PISTON SUPERS 50 2T Cylinder Gasket Install a new cylinder gasket on the mating surface between the cylinder crankcase Make sure that the ring end gaps are aligned with the piston ring pins in the ring grooves Lubricate the cylinder inside and piston rings with engine oil and install the piston into the cylinder while compressing the piston rings Be careful not to damage the piston Install the cylinder head Torque 1 5 1 7kg m Install the exhaust muffler and tighten the exhaust muffler joint lock nuts Torque 1 8 2 2kg m Tighten the exhaust muffler lock bolts Torque 3 0 3 6kg m Install the frame covers Install the met in box The installation sequence is the reverse of removal 7 SUPERS 50 2 GENERATOR SERVICE INFORMATION tete diia 7 2 A C GENERATOR REMOVAL 7 3 GENERATOR 7 4 T A C GENERATOR SUPER5O2 _ Torque 0 8 1 2kg m Torque 0 8 1 2kg m 7 1 7 SUPERS 50 2 SERVICE INFORMATION GENERAL INSTRUCTIONS e All A C generator maintenance and inspection be made with the engine installed e Refer to Section 15 for A C generator inspection TORQUE VALUE Flywheel nut 3 5 4 0kg m SPECIAL TOOLS
84. nected first m After connection apply grease to the battery terminals BW Terminal caps shall be installed securely 2 3 2 GENERAL INFORMATION E f the fuse is burned out find the cause and repair it Replace it with a new one according to the specified capacity m After operation terminal caps shall be installed securely B When taking out the connector the lock on the connector shall be released before operation B Hold the connector body when connecting or disconnecting it B Do not pull the connector wire B Check if any connector terminal is bending protruding or loose SUPERS 50 2T 2 GENERAL INFORMATION SUPERS 50 2T B connector shall be inserted completely x E f the double connector has a lock lock it at the correct position B Check if there is any loose wire B Before connecting a terminal check for damaged terminal cover or loose negative terminal m Check the double connector cover for proper coverage and installation E Insert the terminal completely m Check the terminal cover for proper coverage m Do not make the terminal cover opening face up Secure wire harnesses to the frame with their respective wire bands at the X x designated locations Tighten the bands so that only the insulated surfaces contact the wire harnesses 2 5 2 GENERAL INFORMATION SUPERS 50 2T m After clamping check each wire to make sure it is secure
85. one After the engine stops for 30 minutes connect a hose to the fuel enriching circuit and blow the hose with mouth If air cannot be blown into the hose clogged the auto bystarter is faulty Replace it with a new one 11 6 11 CARBURETOR Connect the auto bystarter yellow wire to the battery positive terminal and green black wire to the battery negative terminal and wait 5 minutes Connect a hose to the fuel enriching circuit 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 Set Plate Screws AUTO BYSTARTER REMOVAL Remove the auto bystarter cover Remove the two auto bystarter set plate screws to remove the auto bystarter Auto Bystarter O ring Check the auto bystarter valve and needle for wear or damage Check the O ring for wear or damage Bystarter Needle Bystarter Valve 11 7 11 CARBURETOR 5 8 50 2T AUTO BYSTARTER INSTALLATION Install the auto bystarter into the carburetor body until it bottoms Install the set plate and then tighten the two screws Screws Auto Bystarter Set Plate FLOAT CHAMBER Remove the two float chamber screws and Screws the float chamber Remove the screw and O ring Float Pin O ring Remove the float pin float and float valve Float 11 8 11 CARBURETOR 8 50 2T Float Valve FLOAT FLOAT VALVE INSPECTION Inspect the floa
86. operate Loose or disconnected check operation o m i pointer moving gt Broken wire harness loat up and down Pointer does not Pointer moves 0O Faulty float Check operation of move pointer by opening and shorting fuel unit E S arness side Pointer does not Pointer moves Q Broken or shorted fuel move unit wire Check connectors for proper connection Loose or disconnected Faulty Incorrectly connected connector Broken or shorted wire in fuel gauge 2 Pointer fluctuates or swings Ignition switch ON Inspection Adjustment Symptom Probable Cause Check battery circuit by operating turn signals and horn Remove fuel unit and check operation of poiner by moving loat up and down Move float up and down rapidly 1 round sec to check the operation of pointer O Burned out fuse gt Weak or dead battery Signals operate Signals dim remain Faulty ignition switch properly on or don t operate Loose or disconnected connector z Broken wire harness Pointer moves Pointer does not Poor contact in fuel unit move gt Check connectors for proper connection Pointer moves in Pointer does not T accordance with move in accord 9 damping oil float ance with float in
87. pection Adjustment Symptom Probable Cause Check battery circuit by operating turn signals Signals operate Signals dim remain properly on or don t operate Weak or dead battery Connect starter motor directly to gt battery Starter motor Starter motor me 51056 or Oseonnectos turns slowly turns normally _ Faulty starter relay Rotate crankshaft gt Turns easily Hard to turn 0 Seized cylinder Broken or shorted starter motor cable Faulty starter pinion 3 Starter motor does not stop turning Inspection Adjustment Symptom Probable Cause Turn ignition switch OFF Not stopped Stopped t Faulty starter pinion Starter relay shorted or stuck closed 2 31 3 INSPECTION ADJUSTMENT SUPERS 50 2T INSPECTION ADJUSTMENT INSPECTION AND MAINTENANCE SCHEDULE 3 1 eet AAA ea 3 4 MOVING DEVICE srren T 3 6 DAMPING DEVIGE 35 aaa aasan sssi 3 7 POWER DRIVE SYSTEM eiii m Dd d 3 7 ELECTRICAL EQUIPMENT eet tees 3 8 ENGINE usse eee DAMES AM UICE 3 9 OTHERS c 3 12 3 INSPECTION ADJUSTMENT SUPERS 50 2T INSPECTION AND MAINTENANCE SCHEDULE Note 1 means time for inspection 2 yxmeans regular replacement for the specified parts This inspection and maintenance
88. r Compress the brake caliper seat and press down the fixed reed to take out the brake pads SUPERS 50 2T Front Brake Caliper Reservoir Fixed Reed 13 8 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPERS 50 2T Fixed Reed Install the brake pads in the reverse order of removal Tighten the brake pad pin bolt Torque 1 5 2 0kg m gt Keep grease or oil off the brake pads to avoid brake failure BRAKE DISK Measure the brake disk thickness Service Limit 3 0mm Measure the brake disk runout Service Limit 0 3mm BRAKE MASTER CYLINDER REMOVAL First drain the brake fluid from the hydraulic brake system When servicing the brake system use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid e When removing the brake fluid tube bolt be sure to plug the tube end to avoid brake fluid leakage DISASSEMBLY Remove the piston rubber cover and snap ring from the brake master cylinder Snap Ring 13 9 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER8 50 2T Diaphragm Main Master Cylinder INSPECTION Measure the brake master cylinder Inspect the master cylinder for scratches or cracks Service Limit 12 75mm d Snap Ring Spring Measure the brake master cylinder piston O D Service Limit 12 75 Before asse
89. r brake performance Disk Brake e Air in brake system e Deteriorated brake fluid e Contaminated brake pads and brake disk e Worn brake pads e Worn brake master cylinder piston oil seal e Clogged brake fluid line e Deformed brake disk e Unevenly worn brake caliper 13 3 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPERS 50 2T FRONT WHEEL REMOVAL Remove the motorcycle front wheel off the ground Disconnect the speedometer cable Remove the front axle 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 the total indicator reading Service Limit 0 2mm replace if over WHEEL RIM Check the wheel rim run out Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over 13 4 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPERS 50 2T FRONT WHEEL BEARING Remove the side collar and dust seal Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly Also check if the outer race fits tightly in the hub Replace the bearings if the 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
90. rque 3 5 4 0kg m gt Keep grease or oil off the drive belt and drive pulley faces STARTER PINION REMOVAL Remove the left crankcase cover gt 8 4 Remove the drive pulley 28 8 Remove the starter pinion Starter Pinion INSPECTION Shaft Forcing Parts Inspect the starter pinion seat for wear Inspect the starter pinion for smooth operation Inspect the starter pinion shaft forcing parts for wear and damage INSTALLATION Apply a small amount of grease to the starter pinion teeth Install the starter pinion in the reverse order of removal Starter Pinion 8 11 8 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY ESUPER8SO2T CLUTCH DRIVEN PULLEY CLUTCH DRIVEN PULLEY REMOVAL Remove the drive pulley 28 8 Hold the clutch outer with the universal holder and remove the 10mm clutch outer nut Remove the clutch outer 10mm Clutch Outer Nut Clutch Outer Universal Holder Remove the clutch driven pulley Remove the drive belt from the clutch driven pulley CLUTCH DRIVEN PULLEY DIS Clutch Driven Pulley Compress the clutch driven pulley spring with the clutch spring compressor and remove the 28mm drive plate nut Remove the driven face spring 2 8 12 8 KICK STARTER DRIVE PULLEY _ CLUTCH DRIVEN PULLEY SUPERS 50 27 Remove the seal collar Seal Collar Driven Pulley Oil Seal Pull out the guide roller pins from the driven pulley and t
91. t e Weak battery e Poorly connected wire e Faulty winker Light dims e Faulty ignition coil e Wire or switch resistance too high e Faulty regulator rectifier Headlight does not change when dimmer switch is turn to Hi or Lo e Faulty or burned bulb e Faulty dimmer switch 16 1 Motor oil indicator light does not come on when motor oil is insufficient e Fuse burned out e Dead battery e Faulty ignition switch e Faulty instrument e Faulty oil meter Motor oil indicator light winks Loose wire connection e Broken wire e Faulty oil meter Fuel gauge pointer does not register correctly e Disconnected wire or connector e Broken wire e Faulty float e Faulty fuel unit e Faulty instrument Fuel gauge pointer fluctuates or swings e Loose wire connection e Faulty fuel unit e Faulty instrument 16 INSTRUMENT SWITCHES LIGHTS SUPERS 50 2T Fuel Unit FUEL UNIT No Smoking REMOVAL Remove the seat 2 4 Remove the body cover 2 5 Disconnect the fuel unit wire connectors Do not damage the fuel unit wire Remove the fuel unit Be careful not to bend or damage the fuel unit float arm INSPECTION Remove the fuel unit Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions RESISTANCES Unit G YAN 20 40 560 580 FUEL GAUGE INSPECTION Connect the fuel unit wire connectors and turn the ignition switch ON
92. t 10mm flange bolt nut 2 12 2 GENERAL INFORMATION SUPERS 50 2T SPECIAL TOOLS Tool Name Drive shaft bearing removal installation Universal bearing puller Lock nut wrench 39mm i Lock nut socket wrench Lock nut wrench Crankcase puller Bearing remover set 12mm Spindle assy 15mm Remover weight Bearing remover set 15mm Spindle assy 15mm Remover head 15mm Remover shaft 15mm Drive shaft bearing removal installation Bearing outer driver 28x30mm Bearing remover Driven pulley outer bearing installation Driven pulley disassembly assembly Driven shaft crankshaft amp crankcase assembly Crankshaft amp crankcase assembly assembly installation Drive shaft bearing installation Final shaft bearing installation Clutch spring compressor Crankcase assembly collar Crankcase assembly tool Rear shock absorber remover Bearing installation Ball race remover Rear shock absorber compressor Float level gauge Lock nut socket wrench 32mm Universal holder Flywheel puller Pilot 12mm Bearing outer driver 32x35mm 2 13 2 GENERAL INFORMATION SUPERS 50 2T Drive shaft bearing installation Final shaft Bearing outer driver 37x40mm bearing installation Crankshaft bearing installation zaam foen pula beara raion varias Umm fore stateam natator snap 2 1 outer driver 42x47mm
93. t and check if the front brake fluid level is within the specified limits through the front brake master cylinder check hole Brake Master Cylinder 3 INSPECTION ADJUSTMENT MOVING DEVICE TIRES Tire Pressure Check the tire pressure gt Tire pressure should be checked when tires are cold Tire Pressure one rider Front 1 75 kg cm2 Rear 2 25 kg cm2 Tire Size Front 120 70 14 50P 120 80 14 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 Rim Spoke Plate Damage Check the wheel rim and spoke plate for wear or damage and measure the rim runout SUPERS 50 2T Front Wheel Axle Nut Rear Wheel Axle Nut 3 6 3 INSPECTION ADJUSTMENT SUPERS 50 2T DAMPING DEVICE SHOCK ABSORBERS Oil Leak Damage Fully apply the front brake and check the action of the front shock absorber by compressing it several times Check the entire shock absorber assembly for looseness or damage Check the action of the rear shock absorber by compressing it several times 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 the oil check bolt Place the motorcycle
94. t for damage or fuel inside the float Check the float valve seat for wear or damage Float Seat Main Jet JETS SCREWS REMOVAL Before removing the throttle stop screw or air screw record the number of rotations until it seats lightly Then remove them Do not force the air screw against its seat to prevent damage Remove the main jet and needle jet holder Throttle Stop Screw Air Screw CARBURETOR PASSAGES CLEANING Blow compressed air through all passages of the carburetor body with an air gun 11 9 11 CARBURETOR SUPERS 50 2T Needle Jet holder Main Jet FLOAT CHAMBER ASSEMBLY Install the main jet needle holder Install the air screw and throttle stop screw according to the rotations recorded If the air screw must be replaced be sure to perform the air screw adjustment again 7 d 2 Air Screw Throttle Stop Screw Slow Jet Float Pin Install the float valve float and float pin Tighten the float screw securely FLOAT LEVEL 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 range Install the O ring Check the operation of the float and install the float chamber Tighten the screws 11 CARBURETOR SUPERS 50 2T O rings CARBURETOR INSTALLATION When installation do not allow foreign partic
95. t never be on the closed side of the index mark otherwise engine damage will occur because of insufficient lubrication If the oil pump is not synchronized properly the following will occur e Excessive white smoke or hard starting due to pump control lever excessively open e Seized piston due to pump control lever insufficiently open 3 11 3 INSPECTION ADJUSTMENT SUPERS 50 2T FUEL SYSTEM Throttle Grip Free Play Measure the throttle grip free play Free Play 2 6mm If the throttle grip free play does not 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 headlight adjusting bolt and moving the adjusting bolt forward and backward to a proper position Tighten the adjusting bolt Headlight Adjusting Bolt 3 12 4 LUBRICATION SYSTEM SUPERS 50 2T LUBRICATION SYSTEM SERVICE INFORMATION eri eet pu en RR P pb ren re RR RAM RU 4 2 TROUBLESHOOTING actos 4 2 Olt PUMP REMONVAL ie tas 4 3 OIL PUMP INSPECTION i ea teneo diners 4 3 OIL PUMP INSTALLATION u u u eer a Marne ye Re 4 4 OIL PUMP BEEEDING u ritenute tere ces quis da 4 5 OILS TAIN qm
96. torcycle for charging Do not remove the electrolyte cap e Do not quick charge the battery Quick charging should only be done in an emergency e Charge the battery according to the charging current and time specified on the battery e When charging check the voltage open voltage with an electric tester e When replacing the battery do not use a traditional battery SPECIFICATIONS SUPER8 50 2T Capacity 12V6AH Voltage 13 0 13 2V Batter d Charging Standard 0 4A 5H current 4A 0 5H Spark plug NGK BR8HSA Spark plug gap Primary 0 6 0 0 Ignition coil resistance 2 5 3 8 Secondary without plug 3 2KQ Pulser coil resistance 20 0 1600 13 5 1 BTDC 2000rpm Ignition timing TROUBLESHOOTING CHARGING SYSTEM No power Intermittent power e Dead battery e Loose battery cable connection e Disconnected battery cable e Loose charging system connection e Fuse burned out e Loose connection or short circuit in ignition system e Faulty ignition switch e Loose connection or short circuit in lighting system Low power Charging system failure e Weak battery e Loose broken or shorted wire or connector e Loose battery connection e Faulty regulator rectifier e Charging system failure e Faulty A C generator e Faulty regulator rectifier 15 1 15 ELECTRICAL EQUIPMENT IGNITION SYSTEM No spark at plug e Faulty spark plug e Poorly connected
97. ve the brake caliper seat from the brake caliper Brake Pads 13 11 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK SUPERS 50 2T ABSORBER FRONT FORK Remove the pistons from the brake caliper If necessary use compressed air to squeeze out the pistons through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination 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 fluid Be careful not to damage the piston surface Check each piston for scratches or wear Measure each piston O D with a micrometer gauge Service Limit 33 90mm Check each caliper cylinder for scratches or wear and measure the cylinder bore Service Limit 33 45mm Compressed Air 13 12 13 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPERS 50 2T ASSEMBLY Clean all removed parts Apply silicon grease to the pistons and oil seals Lubricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved side facing out Install the piston with its outer end protruding 3 5mm beyond the brake caliper cylinder Fixed Reed Wipe off excessive brake fluid with a clean shop towel Apply silicon grease to the brake caliper seat pin and caliper inside

Service Manual - Kymco Spare Parts

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