1. general information super8 50 1 - nazwa.pl · tool boox e033 special tools storage tappet...
TRANSCRIPT
1. GENERAL INFORMATION
1-1
SUPER8 50
Location of Engine Serial Number
Frame Serial Number
1
ENGINE SERIAL NUMBER
1ENGINE SERIAL NUMBER ...................1- 1 LUBRICATION POINTS .......................1-13
SPECIFICATIONS ...................................1- 2 CABLE & HARNESS ROUTING ............1-15
SERVICE PRECAUTIONS......................1- 3 WIRING DIAGRAM................................1-20
TORQUE VALUES ..................................1-11 TROUBLESHOOTUNG ..........................1-21
SPECIAL TOOLS .....................................1-12
1. GENERAL INFORMATION
1-2
SUPER8 50
SPECIFICATIONS
Motorcycle Name & Type SUPER8 50Name & Model No. LEJ2Overall length (mm) 1940Overall width (mm) 745Overall height (mm) 1220Wheel base (mm) 1365Engine type O.H.C.Displacement 50ccFuel Used 92# nonleaded gasoline
Front wheel 43Net weight (kg) Rear wheel 55
Total 108Front wheel 45
Gross weight(kg) Rear wheel 67Total 144
Front wheel 100/80 -14 56JTires Rear wheel 120/80 -14 56JGround clearance (mm) 112
Perform- Braking distance (m) 4 (Initial speed20km/h)
ance Min. turning radius (m) 1.99
Starting system Starting motor &kick starter
Type Gasoline, 4-strokeCylinder arrangement Single cylinderCombustion chamber type Semi-sphereValve arrangement O.H.C.Bore x stroke (mm) φ39.0 x 41.4Compression ratio 11Compression pressure(kg/cm²-rpm) 18Max. output 2.4/7500kw/(r/min)Max. torque 3.2/7000kg m/rpm
Open 3°Port
IntakeClose 7°
Engine
timing Open 9°Exhaust Close 1°
Valve clearance Intake 0.04(cold) (mm) Exhaust 0.04Idle speed (rpm) 1900±100rpm
Lubrication type Forced pressure &wet sump
Oil pump type Inner/outer rotor typeOil filter type Full-flow filtration
LubricationSystem
Oil capacity 0.8 literCooling Type Forced air cooling
Air cleaner type & No Paper element, wetFuel capacity 6.0 liter
Type CVKPiston dia. (mm) 18Venturi dia.(mm) φ18.5equivalent
Carburetor Throttle type Butterfly type
Type CDIIgnition timing BTDC28°/4000rpmContact breaker Non-contact point type
Spark plug NGK C7HSA
Spark plug gap 0.6~0.7mmBattery Capacity 12V7AHClutch Type Dry multi-disc clutch
Type Non-stage transmission
Operation Automatic centrifugaltype
Type Two-stage reductionReduction 1st 0.8-3.1ratio 2nd 11.05
Front Caster angle 27°Axle Trail length ⎯
Tire pressure Front 1.75(kg/cm²) Rear 2.25Turning Left 45°angle Right 45°
Front DISK (180mm) brakeBrake systemtype Rear Drum (110mm) brake
Front TELESCOPESuspension typeRear Unit SwingFront 80Shock absorber
distance Rear 82Frame type Under Bone
Fuel SystemElectrical Equipm
ent
Ignition System
Power D
rive System
Transmis-
sion Gear
Reduction
Gear
Moving D
eviceD
amping
Device
1. GENERAL INFORMATION
1-3
SUPER8 50
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,circlips, cotter pins, etc. whenreassembling.
When tightening bolts or nuts, begin withlarger-diameter to smaller ones at severaltimes, and tighten to the specified torquediagonally.
Use genuine parts and lubricants
.
When servicing the motorcycle, be sure touse special tools for removal andinstallation.
After disassembly, clean removed parts.Lubricate sliding surfaces with engine oilbefore reassembly.
1. GENERAL INFORMATION
1-4
SUPER8 50
Apply or add designated greases andlubricants to the specified lubricationpoints.
After reassembly, check all parts for propertightening and operation.
When two persons work together, payattention to the mutual working safety.
Disconnect the battery negative (-) terminalbefore operation.When using a spanner or other tools, makesure not to damage the motorcycle surface.
After operation, check all connectingpoints, fasteners, and lines for properconnection and installation.When connecting the battery, the positive(+) terminal must be connected first.After connection, apply grease to thebattery terminals.Terminal caps shall be installed securely.
1. GENERAL INFORMATION
1-5
SUPER8 50
If the fuse is burned out, find the cause andrepair it. Replace it with a new oneaccording to the specified capacity.
After operation, terminal caps shall beinstalled securely.
When taking out the connector, the lock onthe connector shall be released beforeoperation.
Hold the connector body when connectingor disconnecting it.Do not pull the connector wire.
Check if any connector terminal is bending,protruding or loose.
ConfirmCapacity
1. GENERAL INFORMATION
1-6
SUPER8 50
The connector shall be insertedcompletely.If the double connector has a lock, lockit at the correct position.Check if there is any loose wire.
Before connecting a terminal, check fordamaged terminal cover or loosenegative terminal.
Check the double connector cover forproper coverage and installation.
Insert the terminal completely.Check the terminal cover for propercoverage.Do not make the terminal cover openingface up.
Secure wire harnesses to the frame withtheir respective wire bands at thedesignated locations.Tighten the bands so that only the insulatedsurfaces contact the wire harnesses.
Snapping!
1. GENERAL INFORMATION
1-7
SUPER8 50
After clamping, check each wire to makesure it is secure.
.
Do not squeeze wires against the weld orits clamp
After clamping, check each harness tomake sure that it is not interfering with anymoving or sliding parts.
When fixing the wire harnesses, do notmake it contact the parts which willgenerate high heat.
Route wire harnesses to avoid sharp edgesor corners. Avoid the projected ends ofbolts and screws.Route wire harnesses passing through theside of bolts and screws. Avoid theprojected ends of bolts and screws.
No Contact !
1. GENERAL INFORMATION
1-8
SUPER8 50
Route harnesses so they are neitherpulled tight nor have excessive slack.
.
Protect wires and harnesses with electricaltape or tube if they contact a sharp edge orcorner
When rubber protecting cover is used toprotect the wire harnesses, it shall beinstalled securely.
Do not break the sheath of wire.If a wire or harness is with a broken sheath,repair by wrapping it with protective tapeor replace it.
When installing other parts, do not press orsqueeze the wires.
Do not pulltoo tight!
Do not press orsqueeze the wire.
1. GENERAL INFORMATION
1-9
SUPER8 50
After routing, check that the wire harnessesare not twisted or kinked.
Wire harnesses routed along withhandlebar should not be pulled tight, haveexcessive slack or interfere with adjacentor surrounding parts in all steeringpositions.
When a testing device is used, make sure tounderstand the operating methodsthoroughly and operate according to theoperating instructions.
Be careful not to drop any parts.
When rust is found on a terminal, removethe rust with sand paper or equivalentbefore connecting.
Do not bend or twist control cables.Damaged control cables will not operatesmoothly and may stick or bind.
Do you understandthe instrument? Isthe instrument setcorrectly?
Remove Rust !
1. GENERAL INFORMATION
1-10
SUPER8 50
Symbols:The following symbols represent theservicing methods and cautions included inthis service manual.
: Apply engine oil to thespecified points. (Usedesignated engine oil forlubrication.)
: Apply grease for lubrication.
: Transmission Gear Oil (90#)
: Use special tool.
: Caution
: Warning
( 12-3) : Refer to page 12-3.
Engine Oil
Grease
Gear Oil
Special
*
1. GENERAL INFORMATION
1-11
SUPER8 50
TORQUE VALUES
STANDARD TORQUE VALUESItem Torque (kg-m) Item Torque (kg-m)
5mm bolt, nut6mm bolt, nut8mm bolt, nut10mm bolt, nut12mm bolt, nut
0.45-0.60.6-1.21.8-2.53.0-4.05.0-6.0
5mm screw6mm screw, SH bolt6mm flange bolt, nut8mm flange bolt, nut10mm flange bolt, nut
0.35-0.50.7-1.11.0-1.42.4-3.03.5-4.5
Torque specifications listed below are for important fasteners.
ENGINE
Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks
Cylinder head bolt ACylinder head bolt BOil filter screen capExhaust muffler lock boltCylinder head flange nutValve adjusting lock nutCam chain tensioner slipper boltOil boltClutch outer nutClutch drive plate nutStarter motor mounting boltOil pump boltDrive face nutSpark plugA.C. generator stator boltCam chain tensioner bolt
2412421111231121
66
3067388
102864
101066
0.7-1.10.7-1.11.0-2.00.7-1.11.2-1.6
0.07-0.090.4-0.71.1-1.53.5-4.55.0-6.00.8-1.20.1-0.35.5-6.51.0-1.40.8-1.20.8-1.2
Double end bolt
Double end boltApply oil tothreads
FRAME
Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks
Steering stem lock nutFront axle nutRear axle nutRear shock absorber upper boltRear shock absorber lower boltSpeedometer cable set screwRear shock absorber lock nut
1111111
25.4101410858
8.0-12.05.0-7.0
11.0-13.04.0-5.02.0-3.0
0.45-0.63.0-3.6
U-nutU-nutU-nut
Apply locking agent
1. GENERAL INFORMATION
1-12
SUPER8 50
SPECIAL TOOLS
Tool Name Tool No. Remarks Ref. Page10-310-4Bearing puller 10.12.15.18 mm E037 10.12.15.18mm bearing12-6
Bushing remover L E032 11102 bush engine hanger rubber
Bushing remover S EO19 11203 bush rear cushion under rubber
Crankshaft bearing puller E030 91005 radial bearing
Crankshaft protector E029 13000 crankshaft comp 12mm.14mm
Clutch spring compressor E027 2301a driven pully assy9-99-12
Cushion assemble & disassembletool F004 52400 cushion assy 13-4
Flywheel holder E017 31110 flywheel comp.2310a pully assydriven
9-59-99-1314-714-9
Flywheel puller E002 Left hand thread 27mm 14-7
Long socket wrench 32mm 8angle F002 50306 steering stem 12-2112-22
Oil seal & bearing installer E014 Oil seal & bearing install
Tool boox E033 Special tools storage
Tappet adjuster E036 90012 screw tappet 3-5
7-7Valve spring compressor E038 Valve spring 7-8
1. GENERAL INFORMATION
1-13
SUPER8 50
LUBRICATION POINTS
ENGINE
Lubrication Points Lubricant
Valve guide/valve stem movable part Cam lobes Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod/piston pin hole Connecting rod big end Crankshaft R/L side oil seal Starter reduction gear engaging part Countershaft gear engaging part Final gear engaging part Bearing movable part O-ring face Oil seal lip
•Genuine KYMCO Engine Oil (SAE15W-40) •API−SG Engine Oil
Starter idle gear Friction spring movable part/shaft movable part Shaft movable grooved part Kick starter spindle movable part
High-temperature resistant grease
A.C. generator connector Transmission case breather tube
Adhesive
1. GENERAL INFORMATION
1-14
SUPER8 50
FRAMEThe following is the lubrication points for the frame.Use general purpose grease for parts not listed.Apply clean engine oil or grease to cables and movable parts not specified.This will avoid abnormal noise and rise the durability of the motorcycle.
Rear Wheel Bearings
Main Stand Pivot
Speedometer Gear/ Front WheelBearings/ Brake Cam/ Anchor Pin/Front Shock Absorber LowerMount Bushings/Pivot
Grease
Grease
Grease
Engine OilRear Brake Cable
Brake Cam/Anchor Pin
Grease
GreaseFront Brake LeverPivot
Front Brake Cable/Speedometer Cable/Throttle Cable
Engine/ Oil
1. GENERAL INFORMATION
1-15
SUPER8 50
CABLE & HARNESS ROUTING
Front Stop Switch Wire Rear Stop Switch Wire
Throttle Cable
Regulator/Rectifier
Rear Brake Cable
Speedometer Cable
Horn
Ignition Switch
Winker
Front Brake Fluid Tube
Brake Master Cylinder
1. GENERAL INFORMATION
1-16
SUPER8 50
Regulator/Rectifier
Speedometer Cable
Ignition Switch
Throttle Grip
Rear Brake Lever
Front Brake Fluid Tube
Headlight Resistor
Horn
Control Lighting
1. GENERAL INFORMATION
1-17
SUPER8 50
Starter Relay
Fuse
Battery (+) Cable
Battery (-) Cable
CDI Unit
Fuel Tank
Ignition Coil
1. GENERAL INFORMATION
1-18
SUPER8 50
Throttle CableVacuum Tee
CarburetorOverflow Tube
Fuel Tube
Crankcase BreatherTube
Ignition CoilPrimary Wire
Ignition Wire
Fuel Filter
Auto Cock Assy Fuel
1. GENERAL INFORMATION
1-19
SUPER8 50
Throttle Cable
Fuel Tube
Vacuum Tube
Auto Bystarter
Crankcase Breather Tube
Wire
Crankcase Breather Tube
Throttle Cable
Vacuum Tube
Fuel Unit
Reed Valve
Secondary AirInlet Tube
Air InjectionCut-offValve
Ignition Coil
1. GENERAL INFORMATION
1-20
SUPER8 50
WIRING DIAGRAM
1. GENERAL INFORMATION
1-21
SUPER8 50
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Empty fuel tankClogged fuel line between fueltank and carburetorClogged float oil passageClogged fuel tank cap breatherholeClogged fuel filterClogged fuel strainerFaulty auto fuel valve
Faulty spark plugFouled spark plugFaulty CDI unitFaulty pulser coilBroken or shorted ignition coilBroken or shorted high-tensionwireFaulty ignition switch
Faulty starter clutchValve clearance too smallImproper valve and seat contactWorn cylinder, piston and pistonringsLeaking cylinder head gasketSeized valveImproper valve timing
Faulty auto bystarterAir leaking through intake pipeIncorrect ignition timingIncorrectly adjusted pilot screw
Flooded carburetorFaulty auto bystarterThrottle valve excessively open
Check if fuel reachescarburetor by looseningdrain screw
Remove spark plug andinstall it into spark plugcap to test spark byconnecting it to engineground
Inspection/Adjustment Probable Cause
Spark jumps
Normal compression
Engine does not fire
Weak or no spark
Low or no compression
Engine fires but does not start
Test cylindercompression
Start engine by follow-ing normal startingprocedure
Remove spark plug andinspect again
Symptom
Fuel reaches carburetor
Fuel does not reach carburetor
Wet spark plugDry spark plug
1. GENERAL INFORMATION
1-22
SUPER8 50
ENGINE LACKS POWER
Clogged air cleanerPoor quality fuel (Restricted)Clogged fuel tank cap breather holeClogged exhaust mufflerFaulty auto bystarterSplit carburetor vacuum pistondiaphragmFaulty auto fuel valve
Faulty CDI unit Faulty pulser coil
Improper valve clearanceadjustmentWorn valve seat (valve stem tooprotruding
Improper valve and seat contactWorn cylinder and piston ringsLeaking cylinder head gasketImproper valve timing
Clogged carburetor jets
Fouled spark plugIncorrect heat range plug
Oil level too highOil level too lowOil not changed
Clogged oil pipe
Faulty oil pump
Worn cylinder and piston ringsMixture too leanPoor quality fuelExcessive carbon buildup incombustion chamberIgnition timing too early
Excessive carbon build-up incombustion chamberPoor quality fuelClutch slippingMixture too leanIgnition timing too early
Start engine and acceleratelightly for observation
Inspection/Adjustment Symptom Probable Cause
Engine speedincreases
Correct timing
Engine speed does notincrease sufficiently
Incorrect timing
Check ignition timingusing a timing light
Test cylinder compression
Check carburetor forclogging
Rapidly accelerate or runat high speed
Remove spark plug andinspect
Check if engine overheats
Check valve clearance
Correct Incorrect
Normal compression
Abnormal compression
Remove oil dipstick andcheck oil level and condition
Remove cylinder head oilpipe bolt and inspect
Engine overheats Engine does not overheats
Plug not fouled ordiscolored
Plug fouled or discolored
Correct and not contaminated
Incorrect or contaminated
Valve train lubricatedproperly
Valve train notlubricated properly
Engine does not knock Engine knocks
Not clogged Clogged
1. GENERAL INFORMATION
1-23
SUPER8 50
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Faulty CDI unitFaulty pulser coil
Mixture too rich (turn screwout)Mixture too lean (turn screw in)
Deteriorated O-ringCarburetor not securelytightenedDamaged insulator rubberBroken vacuum tube
Faulty or fouled spark plugFaulty CDI unitFaulty A.C. generatorFaulty ignition coilBroken or shorted spark plugwireFaulty ignition switch
Faulty air cut-off valveDamaged vacuum tubeClogged or damaged air venthole
Remove spark plug andinstall it into spark plugcap to test spark byconnecting it to engineground
Inspection/Adjustment Symptom Probable Cause
Check ignition timing
Check air cut-off valve
Check carburetor gasketfor air leaks
Check carburetor pilotscrew adjustment
Correct timing Incorrect timing
Correctly adjusted
No air leak Air leaks
Good spark Weak or inter- mittent spark
Good Faulty
Incorrectly adjusted
1. GENERAL INFORMATION
1-24
SUPER8 50
POOR PERFORMANCE (AT HIGH SPEED)
Faulty CDI unitFaulty pulser coil
Improperly adjusted valve clearanceWorn camshaftWorn valve seat
Empty fuel tankClogged fuel tube or filterFaulty charcoal canisterFaulty auto fuel valve
Clean and unclog
Cam timing gear aligning marksnot aligned
Faulty spring
Inspection/Adjustment Symptom Probable Cause
Check ignition timing
Check carburetor jetsfor clogging
Check fuel pump forfuel supply
Correct timing Incorrect timing
Check valve springtension
Check valve clearance
Fuel flows freely Fuel flow restricted
Correct Incorrect
Not clogged Clogged
Correctly adjusted Incorrectly adjusted
Not weakened Weak spring
Check valve timing
1. GENERAL INFORMATION
1-25
SUPER8 50
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)
Undercharging
Dead batteryFaulty battery
Faulty A.C. generator coilBroken yellow wireLoose connector
Broken red wire
Faulty regulator/rectifierPoorly connected coupler
Faulty A.C. generator
Overcharging
Broken green wire
Poorly connected coupler
Faulty regulator/rectifier
Start engine and testlimit voltage betweenbattery terminals
Connect battery (+) wireto regulator/rectifiercoupler red wire andbattery (-) wire to engineground and test voltage
Inspection/Adjustment
Inspection/Adjustment
Symptom
Symptom
Probable Cause
Probable Cause
Normal voltage
Battery has voltagewith ignitionswitch “ON”
Normal
Voltage does notincrease
Battery has novoltage with ignitionswitch “ON”
Resistance too high
Normal voltage No voltage
Measure resistancebetween AC generatorcoil terminals
Normal Abnormal
Check regulator/rectifiercoupler for looseconnection
Normal Abnormal
Connect battery (+) wireto regulator/rectifiercoupler green wire andbattery (-) wire to engineground and test voltage
Check regulator/rectifiercoupler for looseconnection
1. GENERAL INFORMATION
1-26
SUPER8 50
NO SPARK AT SPARK PLUG
Faulty old spark plug
Loose spark plug cap
Poorly connected coupler
Faulty ignition switchFaulty pulser coilFaulty ignition coil
Broken wire harnessPoorly connected coupler
Faulty CDI unit
Faulty ignition coil
Replace with a newspark plug and inspectagain
Check CDI unit couplerfor looseness
Inspection/Adjustment Symptom Probable Cause
Normal
Abnormal
Normal
Abnormal
Normal Abnormal
Abnormal
Measure resistancebetween CDI unitcoupler wire terminals
Check related parts
Check ignition coil witha CDI unit tester
Weak or no spark
Not loose
Good spark
Loose
Good Good
Check spark plug capand high-tension wirefor looseness
Check CDI unit with aCDI unit tester