KYMCO Super 9 50 User manual

SUPER 9 50
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO Super9 50.
Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before any
operation is started.
Section 2 is the removal/installation
procedures for the frame covers which are
subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part, starting
from periodic maintenance.
Sections 5 through 12 give instructions
for disassembly, assembly and adjustment
of engine parts. Section 13 is the removal/
installation of chassis. Section 15 states
the testing and measuring methods of
electrical equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages give
detailed procedures for the section.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION 1
EXHAUST MUFFLER/FRAME COVERS 2
INSPECTION/ADJUSTMENT 3
LUBRICATION SYSTEM 4
ENGINE REMOVAL/INSTALLATION 5
CYLINDER HEAD/CYLINDER/PISTON 6
KICK STARTER/DRIVE
PULLEY/CLUTCH/DRIVEN PULLEY 7
FINAL REDUCTION 8
A.C. GENERATOR 9
CRANKCASE/CRANKSHAFT 10
COOLING SYSTEM 11
CARBURETOR 12
STEERING HANDLEBAR/FRONT
WHEEL/FRONT BRAKE/FRONT
SHOCK ABSORBER/FRONT FORK 13
REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER` 14
ELECTRICAL EQUIPMENT 15
INSTRUMENT/SWITCHES/LIGHTS 16
EVAPORATIVE/EXHAUST EMISSION
CONTROL SYSTEM 17
CHASSIS ELECTRICAL
E
Q
UIPMENT
ENGINE
The information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.
＊
E/M

1. GENERAL INFORMATION
1-0
SUPER 9 50
1
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
GENERAL INFORMATION
__________________________________________________________________________________
ENGINE SERIAL NUMBER---------------------------------------------- 1- 1
SPECIFICATIONS---------------------------------------------------------- 1- 2
SERVICE PRECAUTIONS------------------------------------------------ 1- 4
TORQUE VALUES --------------------------------------------------------- 1-14
SPECIAL TOOLS ----------------------------------------------------------- 1-15
LUBRICATION POINTS -------------------------------------------------- 1-16
WIRING DIAGRAM-------------------------------------------------------- 1-22
TROUBLESHOOTING----------------------------------------------------- 1-24
1

1. GENERAL INFORMATION
1-1
SUPER 9 50
ENGINE SERIAL NUMBER
Location of Engine Serial Numbe
r
Location of Frame Serial Numbe
r
Vehicle Identification Serial Numbe
r

1. GENERAL INFORMATION
1-2
SUPER 9 50
SPECIFICATIONS
Name & Model No. SH10DA
Overall length 1850mm
Overall width 700mm
Overall height 1190mm
Wheel base 1295mm
Engine type Water cooled 2-stroke
Displacement 49.4cc
Fuel Used 92# nonleaded gasoline
Front wheel 41
Net weight (kg) Rear wheel 61
Total 102
Front wheel 95
Gross weight(kg) Rear wheel 138
Total 233
Front wheel 120/70-12
Rear wheel 130/70-12
Ground clearance 160mm
Perform- Braking distance (m) 4.4m /30km/HV
ance Min. turning radius 2150mm
Starting system Starting motor &
kick starter
Type Gasoline,2-stroke
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Bore x stroke (mm) 39 x 41.4
Compression ratio 7.2:1
Compression pressure
(kg/cm²-rpm) 11.8
Max. output (ps/rpm) 3.6/6500
Max. torque (N-m/rpm) 3.92/6000
Intake Open Automatic controlled
Port (1mm) Close Automatic controlled
timin
g
Exhaust Open
(1mm) Close
Valve Intake
clearance
(
cold
)
Exhaust
Idle speed (rpm) 2000±100rpm
Lubrication type Separate type
Oil pump type Plunger type
Oil filter type Full-flow filtration
Oil capacity 1.7 liters
Exchanging capacity 1.4 liters
Cooling Type Water cooling
Air cleaner type & No Sponge wet
Gear oil capacity 0.12 liters
Fuel capacity 6.8 liters
Type ＰＢ
Piston dia. 13
Venturi dia. 14 equivalent
Type CDI
Ignition timing 13.5°±2°/2000rpm
Spark plug NGK
BR8HSA
Spark plug gap 0.6～0.7mm
Battery Capacity 12V4AH
Clutch Type Dry multi-disc clutch
Type Non-stage transmission
Operation Automatic centrifugal
type
Type Two-stage reduction
Reduction 1st
ratio 2nd
Front Caster angle
Axle Connecting rod
Tire
p
ressure Fron
t
1.75
(kg/cm²)Rear 2.25
Turning Left 42.5°
angle Right 42.5°
Brake s
y
ste
m
Fron
t
Disk brake
type Rear Disk brake
Sus
p
ension Fron
t
Telesco
p
e
type Rear Unit swing
Shock absorbe
r
Front Telescope
type Rear Double swing
Frame type Under bone
Tires
Engine
Fuel S
y
stem
Carbureto
r
Electrical E
q
ui
p
ment Power Drive System
Transmis- sion Gear Reduction
Gear
Moving Device Damping
Device
Lubrication S
y
stem
I
g
nition S
y
stem

1. GENERAL INFORMATION
1-3
SUPER 9 50
Name & Model No. SF10DA
Overall length 1850mm
Overall width 700mm
Overall height 1190mm
Wheel base 1295mm
Engine type Air cooled 2-stroke
Displacement 49.4cc
Fuel Used 92# nonleaded gasoline
Front wheel 41.5
Net weight (kg) Rear wheel 64.5
Total 106
Front wheel 83.5
Gross weight(kg) Rear wheel 132.5
Total 216
Front wheel 120/70-12
Rear wheel 130/70-12
Ground clearance 160mm
Perform- Braking distance (m) 4.4m /30km/HV
ance Min. turning radius 2150mm
Starting system Starting motor &
kick starter
Type Gasoline,2-stroke
Cylinder arrangement Single cylinder, flat
Combustion chamber type Semi-sphere
Bore x stroke (mm) 39 x 41.4
Compression ratio 7.2:1
Compression pressure
(kg/cm²-rpm) 11.8
Max. output (ps/rpm) 4.2/6500
Max. torque (N-m/rpm) 4.9/6000
Intake Open Automatic controlled
Port (1mm) Close Automatic controlled
timin
g
Exhaust Open
(1mm) Close
Valve Intake
clearance
(
cold
)
Exhaust
Idle speed (rpm) 1900±100rpm
Lubrication type Separate type
Oil pump type Plunger type
Oil filter type Full-flow filtration
Oil capacity 1.7 liters
Exchanging capacity 1.4 liters
Cooling Type Air cooling
Air cleaner type & No Sponge wet
Gear oil capacity 0.12 liters
Fuel capacity 6.8 liters
Type ＰＢ
Piston dia. 13
Venturi dia. 14 equivalent
Type CDI
Ignition timing 13.5°±2°/2000rpm
Spark plug NGK
BR8HSA
Spark plug gap 0.6～0.7mm
Battery Capacity 12V4AH
Clutch Type Dry multi-disc clutch
Type Non-stage transmission
Operation Automatic centrifugal
type
Type Two-stage reduction
Reduction 1st
ratio 2nd
Front Caster angle
Axle Connecting rod
Tire
p
ressure Fron
t
1.75
(kg/cm²)Rear 2.25
Turning Left 42.5°
angle Right 42.5°
Brake s
y
ste
m
Fron
t
Disk brake
type Rear Expanding brake
Sus
p
ension Fron
t
Telesco
p
e
type Rear Unit swing
Shock absorbe
r
Front Telescope
type Rear Double swing
Frame type Under bone
Tires
Engine
Fuel S
y
stem
Carbureto
r
Electrical E
q
ui
p
ment Power Drive System
Transmis- sion Gear Reduction
Gear
Moving Device Damping
Device
Lubrication S
y
stem
I
g
nition S
y
stem

1. GENERAL INFORMATION
1-4
SUPER 9 50
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
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.
When servicing the motorcycle, be sure
to use special tools for removal and
installation.
After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.
K
YMCO
K
YMCO
K
YMCO

1. GENERAL INFORMATION
1-5
SUPER 9 50
Apply or add designated greases and
lubricants to the specified lubrication
points.
After reassembly, check all parts for
proper tightening and operation.
When two persons work together, pay
attention to the mutual working safety.
Disconnect the battery negative (-)
terminal before operation.
When using a spanner or other tools,
make sure not to damage the motorcycle
surface.
After operation, check all connecting
points, fasteners, and lines for proper
connection and installation.
When connecting the battery, the positive
(+) terminal must be connected first.
After connection, apply grease to the
battery terminals.
Terminal caps shall be installed securely.
K
YMCO

1. GENERAL INFORMATION
1-6
SUPER 9 50
If the fuse is burned out, find the cause
and repair it. Replace it with a new one
according to the specified capacity.
After operation, terminal caps shall be
installed securely.
When taking out the connector, the lock
on the connector shall be released before
operation.
Hold the connector body when
connecting or disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is
bending, protruding or loose.
Confir
m
Capacity

1. GENERAL INFORMATION
1-7
SUPER 9 50
The connector shall be inserted
completely.
If the double connector has a lock,
lock it at the correct position.
Check if there is any loose wire.
Before connecting a terminal, check
for damaged terminal cover or loose
negative terminal.
Check the double connector cover for
proper coverage and installation.
Insert the terminal completely.
Check the terminal cover for proper
coverage.
Do not make the terminal cover opening
face up.
Secure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.
Sna
pp
in
g
!

1. GENERAL INFORMATION
1-8
SUPER 9 50
After clamping, check each wire to make
sure it is secure.
Do not squeeze wires against the weld or
its clamp.
After clamping, check each harness to
make sure that it is not interfering with
any moving or sliding parts.
When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
Route wire harnesses to avoid sharp
edges or corners. Avoid the projected
ends of bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
N
o Contact !

1. GENERAL INFORMATION
1-9
SUPER 9 50
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.
When rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
Do not break the sheath of wire.
If a wire or harness is with a broken
sheath, repair by wrapping it with
protective tape or replace it.
When installing other parts, do not press
or squeeze the wires.
Do not pull too
tight!
Do not press or
squeeze the wire.

1. GENERAL INFORMATION
1-10
SUPER 9 50
After routing, check that the wire
harnesses are not twisted or kinked.
Wire harnesses routed along with
handlebar should not be pulled tight,
have excessive slack or interfere with
adjacent or surrounding parts in all
steering positions.
When a testing device is used, make sure
to understand the operating methods
thoroughly and operate according to the
operating instructions.
Be careful not to drop any parts.
When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Do you understand the
instrument? Is the
instrument set
l?
Remove Rust !

1. GENERAL INFORMATION
1-11
SUPER 9 50
Symbols:
The following symbols represent the
servicing methods and cautions included
in this service manual.
: Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
: Apply grease for
lubrication.
: Transmission Gear Oil
(90#)
: Use special tool.
: Caution
: Warning
Special
Engine Oil
Grease
Gear Oil
＊

1. GENERAL INFORMATION
1-12
SUPER 9 50
SERVICE INFORMATION
ENGINE Standard (mm) Service Limit (mm)
Item SF10DA SH10DA SF10DA SH10DA
Cylinder head warpage ⎯⎯0.10 0.10
Piston O.D.(5mmfrom bottom of piston skirt) 38.955～38.970 38.955～38.970 38.90 38.90
Cylinder-to- piston clearance 0.03～0.07 0.10 0.10
Piston pin hole I.D. 12.002～12.008 12.002～12.008 12.03 12.03
Piston pin O.D. 11.994～12.0 11.994～12.0 11.98 11.98
Piston-to-piston pin clearance 0.002～0.014 ←0.03 ←
Piston ring end gap (top/second) 0.10～0.25 0.10～0.25 0.40 0.40
Connecting rod small end I.D. 17.005～17.017 17.005～17.017 17.03 17.03
Cylinder bore 39.0～39.025 39.0～39.025 39.05 39.05
Drive belt width 18 18 17 17
Drive pulley collar O.D. 20.01～20.025 20.01～20.025 19.97 19.97
Movable drive face ID. 20.035～20.085 20.035～20.085 20.21 20.21
Weight roller O.D. 13.0 13.0 12.4 12.4
Clutch outer I.D. 107～107.2 107～107.2 107.5 107.5
Driven face spring free length 87.9 87.9 82.6 82.6
Driven face O.D. 33.965～33.985 ←33.94 ←
Movable driven face I.D. 34.0～34.025 ←34.06 ←
Connecting rod big end side clearance ⎯←
0.60 ←
Connecting rod big end radial clearance ⎯←
0.04 ←
Crankshaft runout A/B ⎯⎯
L:0.15 R:0.10 ←
CARBURETOR SF10DA SH10DA
Venturi dia. 14mm 14mm
I
de
ntifi
c
ati
o
n n
u
m
ber
PB
058
PB
093
Float level 8.6mm 8.6mm
Main jet(Unlimited/limited speed) #92/#78 #92/#78
Slow jet #35 #35
Air screw opening 1¼±½1¼±½
Idle speed 1900±100rpm 2000±100rpm
Throttle grip free play 2～6mm 2～6mm
Jet needle clip notch 1st notch 1st notch
CC

1. GENERAL INFORMATION
1-13
SUPER 9 50
FRAME
Standard (mm) Service Limit (mm)
Item SF10DA SH10DA SF10DA SH10DA
Axle shaft runout ⎯⎯0.2 0.2
Radial
Front wheel rim runout Axial
Front shock absorber spring free length 221.5 221.5 204.3 204.3
Rear wheel rim runout 2.0 2.0
Brake drum I.D. Front/rear 110 110 111 111
Brake lining thickness Front/rear 4.0/4.0 4.0/4.0 2.0/2.0 2.0/2.0
Brake disk runout Front/rear ⎯⎯0.30 0.30
Rear shock absorber spring free length 214.7 214.7 197.7 197.7
ELECTRICAL EQUIPMENT
SF10DA SH10DA
Capacity 12V4AH 12V4AH
Voltage 13.0～13.2V 13.0～13.2V
Charging Standard 0.4A/5H 0.4A/5H
Battery
current Quick 4A/0.5H 4A/0.5H
Spark plug (NGK) BR8HSA BR8HSA
Spark plug gap 0.6～0.7mm 0.6～0.7mm
Primary coil 0.153～0.187Ω0.153～0.187Ω
Secondary coil
(with plug cap) 6.99～10.21KΩ6.99～10.21KΩ
Ignition coil resistance Secondary coil
(without plug cap) 3.24～3.96KΩ3.24～3.96KΩ
Pulser coil resistance (20℃)80～160Ω80～160Ω
Ignition timing 13.5°±2°BTDC/2000rpm 13.5°±2°BTDC/2000rpm

1. GENERAL INFORMATION
1-14
SUPER 9 50
TORQUE VALUES
ENGINE Ite
m
Thread dia.
(
mm
)
Tor
q
ue
(
N-m
)
Remarks
Cylinder head bolt
Clutch drive plate nut
Clutch outer nut
Drive face nut
Oil check bolt
Engine mounting bolt
Engine hanger bracket bolt
Exhaust muffler joint lock nut
Exhaust muffler lock bolt
Spark plug
BF7x115
10
NH10
NH12
10
BF10x95
BF10x50
NC6mm
BF8x35
14.7～16.7
34.3～39.2
34.3～44.1
49.0～58.8
9.8～14.7
44.1～53.9
34.3～44.1
9.8～13.7
29.4～35.3
10.8～16.7
(cold)
(cold)
FRAME Ite
m
Thread dia.
(
mm
)
Tor
q
ue
(
N-m
)
Remarks
Handlebar lock nut
Steering stem lock nut
Steering top cone race
Front axle nut
Rear axle 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
10
25.4
25.4
12
16
8
8
10
8
8
44.1～49.0
78.4～117.6
4.9～12.7
49.0～68.6
107.8～127.4
32.3
32.3
14.7～29.4
14.7～29.4
34.3～44.1
23.5～29.4
14.7～24.5
Flange bolt/U-nut
Flange U-nut
Flange U-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
Ite
m
Tor
q
ue
(
N-m
)
Ite
m
Tor
q
ue
(
N-m
)
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
4.4～5.9
7.8～11.8
17.6～24.5
29.4～39.2
49.0～58.8
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
3.43～4.9
6.86～10.8
9.8～13.7
23.5～29.4
14.7～44.1

1. GENERAL INFORMATION
1-15
SUPER 9 50
SPECIAL TOOLS
Tool Name Tool No. Remarks
Universal bearing puller E030 Crankshaft bearing removal
Lock nut socket wrench F001 Top cone race holding
Lock nut wrench, F001 Stem lock nut tightening
Crankcase puller E026 Crankcase disassembly
Bearing remover set, 12mm
(Spindle assy, 15mm)
(Remover weight)
E020 Drive shaft bearing removal/installation
Bearing remover set, 15mm
(Spindle assy, 15mm)
(Remover head, 15mm)
(Remover shaft, 15mm)
E018 Drive shaft bearing removal/installation
Bearing outer driver, 28x30mm E014 Bearing installation
Clutch spring compressor E027 Driven pulley disassembly/assembly
Crankcase assembly collar E023 Driven shaft, crankshaft & crankcase
assembly
Crankcase assembly tool E024 Crankshaft & crankcase assembly
Ball race remover F005 Steering stem bearing races
Rear shock absorber compressor F004 Rear shock absorber disassembly/assembly
Universal holder E017 Flywheel holding
Flywheel puller E001 Flywheel removal
Pilot, 12mm E020 Drive shaft bearing installation
Bearing outer driver, 32x35mm E014 Drive shaft bearing installation
Final shaft bearing installation
Bearing outer driver, 37x40mm E014 Drive shaft bearing installation Final
shaft bearing installation Crankshaft
bearing installation
Outer driver, 24x26mm E014 Driven pulley bearing installation

1. GENERAL INFORMATION
1-16
SUPER 9 50
LUBRICATION POINTS
ENGINE
NO. Lubrication Points Lubricant Remarks
1 Crankcase sliding & movable JASO-FC or API-TC
2 Cylinder movable parts
3 Transmission gear (final gear) SAE-90#
4 Kick starter spindle bushing Grease
5 Drive pulley movable parts Grease
6 Starter pinion movable parts Grease
FRAME
Apply clean engine oil or grease to cables and movable parts not specified. This will avoid
abnormal noise and rise the durability of the motorcycle.
Front/Rear Brake Leve
r
Seat Loc
k
Throttle Cable
Main Stand Pivot
Grease Engine Oil Grease
Speedometer Gear
/
Brake Cam/Front
Shock Absorber
Lower Mount
Bushings/Pivot
Grease
Grease
Grease Engine Oil
Engine Oil
Speedometer Cable
Rear Wheel
Bearing
Rear Brake Cable

1. GENERAL INFORMATION
1-17
SUPER 9 50
Front Stop
Switch
Rear Stop
Switch
Throttle
Cable
Radiato
r
Brake Maste
r
C
y
linders
Speedomete
r
Cable
Horn
Wire Harness
Water Hose
Reserve Cap
Resistors

1. GENERAL INFORMATION
1-18
SUPER 9 50
Front Brake Fluid Tube
Water Hose
Ignition
Switch
Winke
r
Fuse Box
Starter Rela
y
CDI Unit
Regulator
/
Rectifier