Kymco Super8 50* Factory Service / Repair/ Workshop Manual ! + Parts Catalogue

10. FINAL REDUCTION 10-0 SUPER8 50 10 10

10. FINAL REDUCTION 10-1 SUPER8 50 SERVICE INFORMATION SPECIFICATIONS Specified Oil: GEAR OIL SAE 90# Oil Capacity: At disassembly : 0.2 liter At change : 0.18 liter SPECIAL TOOLS Bearing puller, 10,12,15,18mm TROUBLESHOOTING Engine starts but motorcycle won‘t move • Damaged transmission • Seized or burnt transmission • Faulty drive belt • Faulty clutch Abnormal noise • Worn, seized or chipped gears • Worn bearing Oil leaks • Oil level too high • Worn or damaged oil seal SERVICE INFORMATION .......................10-1 FINAL REDUCTION INSPECTION...... 10-2 TROUBLESHOOTING..............................10-1 BEARING REPLACEMENT .................. 10-3 FINAL REDUCTION DISASSEMBLY ....10-2 FINAL REDUCTION ASSEMBLY........ 10-4

10. FINAL REDUCTION 10-2 SUPER8 50 FINAL REDUCTION DISASSEMBLY Remove the rear brake cable. ( 13-3) Remove the rear wheel. ( 13-2) Remove the left crankcase cover. ( 9-2) Remove the clutch/driven pulley. ( 9-10) 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. Remove the final gear and countershaft. FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage. Inspect the final gear and final shaft for wear, damage or seizure. Final Gear Countershaft Drive Shaft Countershaft Bolt Final Shaft

10. FINAL REDUCTION 10-3 SUPER8 50 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. BEARING REPLACEMENT (TRANSMISSION CASE COVER) Remove the transmission case cover bearings using a bearing puller. Remove the final shaft oil seal. Bearing Puller Drive new bearings into the transmission case cover. Drive Shaft Bearing Final Shaft Bearing Countershaft Bearing Drive Shaft Bearing Do not remove the transmission case cover except for necessary part replacement. When replacing the drive shaft, also replace the bearing and oil seal. ＊ Bearing Puller Oil Seal Final Shaft Bearing Countershaft Bearing Outer Driver, 32x35mm Special

10. FINAL REDUCTION 10-4 SUPER8 50 BEARING REPLACEMENT (LEFT CRANKCASE) Remove the drive shaft. Remove the drive shaft oil seal. Remove the left crankcase bearings using a bearing puller. Bearing Puller Drive new bearings into the left crankcase. Install a new drive shaft oil seal. FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase. Install the final gear and final shaft into the left crankcase. Pilot Drive Shaft Bearing Puller, 12mm Special

Kymco Super8 50* Factory Service / Repair/ Workshop Manual ! + Parts Catalogue

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