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

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

__________________________________________________________________________________

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. GENERAL INFORMATION

1-1

SUPER 9 50

ENGINE SERIAL NUMBER

Location of Engine Serial Numbe

Location of Frame Serial Numbe

Vehicle Identification Serial Numbe

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

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

ressure Fron

1.75

(kg/cm²)Rear 2.25

Turning Left 42.5°

angle Right 42.5°

Brake s

ste

Fron

Disk brake

type Rear Disk brake

Sus

ension Fron

Telesco

type Rear Unit swing

Shock absorbe

Front Telescope

type Rear Double swing

Frame type Under bone

Tires

Engine

Fuel S

stem

Carbureto

Electrical E

ment Power Drive System

Transmis-

sion Gear Reduction

Gear

Moving Device Damping

Device

Lubrication

stem

nition S

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

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

ressure Fron

1.75

(kg/cm²)Rear 2.25

Turning Left 42.5°

angle Right 42.5°

Brake s

ste

Fron

Disk brake

type Rear Expanding brake

Sus

ension Fron

Telesco

type Rear Unit swing

Shock absorbe

Front Telescope

type Rear Double swing

Frame type Under bone

Tires

Engine

Fuel S

stem

Carbureto

Electrical E

ment Power Drive System

Transmis-

sion Gear Reduction

Gear

Moving Device Damping

Device

Lubrication

stem

nition S

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.

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.

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

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

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.

o Contact !

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