KYMCO SUPER 9 50 Scooter Service Repair 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 EQUIPMENT ENGINE The information and contents included in this manual may be different from the motorcycle in case specifications are changed. ＊ E/M Downloaded from www.Manualslib.com manuals search engine

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 Downloaded from www.Manualslib.com manuals search engine

1. GENERAL INFORMATION 1-1 SUPER 9 50 ENGINE SERIAL NUMBER Location of Engine Serial Number Location of Frame Serial Number Vehicle Identification Serial Number Downloaded from www.Manualslib.com manuals search engine

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 timing 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 pressure Front 1.75 (kg/cm²) Rear 2.25 Turning Left 42.5° angle Right 42.5° Brake system Front Disk brake type Rear Disk brake Suspension Front Telescope type Rear Unit swing Shock absorber Front Telescope type Rear Double swing Frame type Under bone Tires Engine Fuel System Carburetor Electrical Equipment Power Drive System Transmis- sion Gear Reduction Gear Moving Device Damping Device Lubrication System Ignition System Downloaded from www.Manualslib.com manuals search engine

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 timing 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 pressure Front 1.75 (kg/cm²) Rear 2.25 Turning Left 42.5° angle Right 42.5° Brake system Front Disk brake type Rear Expanding brake Suspension Front Telescope type Rear Unit swing Shock absorber Front Telescope type Rear Double swing Frame type Under bone Tires Engine Fuel System Carburetor Electrical Equipment Power Drive System Transmis- sion Gear Reduction Gear Moving Device Damping Device Lubrication System Ignition System Downloaded from www.Manualslib.com manuals search engine

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. KYMCO KYMCO KYMCO Downloaded from www.Manualslib.com manuals search engine

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. KYMCO Downloaded from www.Manualslib.com manuals search engine

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. Confirm Capacity Downloaded from www.Manualslib.com manuals search engine

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. Snapping! Downloaded from www.Manualslib.com manuals search engine

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. No Contact ! Downloaded from www.Manualslib.com manuals search engine

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KYMCO SUPER 9 50 Scooter Service Repair Manual

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