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 !