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Kymco Super 9 (SH10DA) servicemanual

1. STARTER MOTOR 1 Starter motor won t turn Inspection Adjustment Symptom Probable Cause Check operation of stop switch by gt Burned out fuse applying brake Ze Weak or dead battery Q Faulty stop switch Stoplight comes on does not Loose or disconnected E connector 07 gt Broken shorted ignition signals switch wire Signals operate Signals dim remain D Faulty or weak battery Check operation of properly on or don t operate starter relay by depressing starter gt button Relay operates Relay does not mO Poor starter button connection Faulty starter relay properly operate L Loose or disconnected Connect starter motor directly to gt battery Starter motor turns Starter does not turn Faulty starter motor Faulty wire harness 2 Starter motor turns slowly or idles Inspection Adjustment Symptom Probable Cause Check battery circuit by operating turn g signals Signals operate Signals dim remain properly don
2. 5 1 REMO V AL 5 2 INSTALLATION DELT 5 5 0 KYMCO 5 ENGINE REMOVAL INSTALLATION SUPER9 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e Parts requiring engine removal for servicing Crankcase Crankshaft TORQUE VALUES Engine mounting bolt 44 1 53 9N m Engine hanger bracket bolt 44 53 9N m Rear shock absorber lower mount bolt 23 5 29 4N m Rear shock absorber upper mount bolt 34 3 44 1N m KYMCO 5 ENGINE REMOVAL INSTALLATION SUPER9 50 ENGINE REMOVAL Clamp Remove the frame body cover 42 2 Remove the brake fluid tube bolt of the rear brake caliper Remove the rear brake caliper bolt and the rear brake caliper Rear Brake Caliper Bolt Disconnect the oil pump control cable from Auto Fuel Valve 24 Line the pump body Disconnect the oil inlet line from the oil pump After the oil inlet line is disconnected plug the oil line opening to prevent oil from flowing out Disconnect the auto bystarter A C generator thermosensor wire couplers and starter motor wire connectors Disconnect the fuel tube and vacuum tube that go to the carburetor from the auto fuel valve Oil Pump Control Cable AC Generator Wire Connector Remove the spark plug cap Water Hose Drain the coolant 3 10 Disconnect the water hose Spark Plug Cap 5 2 KYMCO 5 ENGI
3. This Service Manual describes 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 The information and contents included in this manual may be different from the motorcycle in case specifications are changed KWANG YANG MOTOR CO LTD OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION KYMCO SUPER9 50 TABLE OF CONTENTS EXHAUSTMUFFLERFRAMECOVERS 7 Famenne LUBRICATION SYSTEM ERCINEREMOVALTNSTALLATION 5 CYLINDER HEADICYLINDERIPISTON 6 PULLEY CLUTCH DRIVEN PULLEY PNumpUcnON GENERATOR Ja STEERING HANDLEBAR FRONT i HNIDO
4. Mixture too lean 1 GENERAL INFORMATION KYMCO SUPER9 50 POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Check ignition timing Symptom Correct timing Incorrect timing Probable Cause Faulty CDI unit Check carburetor air screw adjustment Correctly adjusted Incorrectly adjusted Faulty A C generator Q Mixture too rich turn screw Check carburetor gasket for air leaks No air leak Air leaks out Mixture too lean turn screw in O Carburetor not securely tightened Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Good spark Weak or inter mittent spark Remove auto bystarter connecting wire and check if bypass fuel line is clogged Q Faulty intake manifold gasket Deformed carburetor O ring Faulty or fouled spark plug Faulty CDI unit Faulty A C generator Faulty ignition coil Connect auto bystarter wire to battery Wait for 5 minutes then connect a hose to fuel enriching circuit and then blow the hose with mouth Not clogged Clogged
5. Symptom Engine starts but motor cycle does not move Probable Cause O Worn or slipping drive belt Q Broken ramp plate 9 Broken driven face spring Motorcycle creeps or engine starts but soon stops or seems to rush out Rear wheel rotates when engine idles Separated clutch lining 0O Damaged driven pulley shaft splines Damaged final gear Seized final gear r Broken shoe spring Engine lacks power at start of a grade poor slope performance Clutch outer and clutch weight stuck GSeized pivot O Worn or slipping drive belt Worn weight rollers Engine lacks power at high speed Seized drive pulley bearings Weak driven face spring Worn or seized driven pulley bearings r O Worn or slipping drive belt There is abnormal noise or smell while running Worn weight rollers Worn or seized driven pulley bearings Oil or grease fouled drive belt Worn drive belt G Weak driven face spring Worn or seized driven pulley bearings STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Steering is heavy Probable Cause Front and rear tire pressures are normal Q Steering stem nut too tight Front or rear wheel is wobbling Q Broken steering ste
6. 9 50 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER SERVICE INFORMATION TROUBLESHOOTING REAR BRAKE REAR REAR WHEEL REAR BRAKE DRUM REAR SHOCK ABSORBER 14 0 14 BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER SUPER9 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e When performing the services stated in this section the engine and exhaust muffler must be cold to avoid scalding e During servicing keep oil or grease off the brake pads and brake disk SPECIFICATIONS x pem Standard mm Service Limit mm Rear wheel rim runout o S 20 Rear shock absorber spring free length RearbrkedrumLD 10 gd Rearbrakedisk liningthickness 353840 3020 Rear brake disk runout O 0 30 TORQUE VALUES SPECIAL TOOLS Exhaust muffler lock bolt 29 4 39 2N m Rear shock absorber remover Rear axle nut 78 4 98 0N m Shock absorber spring compressor Rear shock absorber lower mount bolt 19 6 29 4N m Rear shock absorber upper mount bolt 39 2N m Rear damper lock n
7. KYMCO 12 CARBURETOR SUPER9 50 Connect the auto bystarter yellow wire to the battery positive terminal and green black wire to the battery negative terminal and wait 5 minutes Connect a hose to the fuel enriching circuit and blow the hose with mouth If air can be blown into the hose the auto bystarter is faulty and replace it with a new one AUTO BYSTARTER REMOVAL Remove the auto bystarter cover Remove the two auto bystarter set plate screws to remove the auto bystarter Auto Bystarter Set Plate Screws Check the auto bystarter valve and needle for wear or damage Check the O ring for wear or damage O ring Bystarter Needle Bystarter Valve 12 6 12 CARBURETOR AUTO BYSTARTER INSTALLATION Install the auto bystarter into the carburetor body until it bottoms Install the set plate and then tighten the two screws FLOAT CHAMBER Remove the two float chamber screws and the float chamber Remove the screw and O ring Remove the float pin float and float valve 12 7 KYMCO SUPER9 50 Auto Bystarter Set Plate Screws Screws Float Pin Float O ring KYMCO 12 CARBURETOR SUPER9 50 FLOAT FLOAT VALVE INSPECTION Float Valve Inspect the float for damage or fuel inside the float Check the float valve seat for wear or damage Float Seat JETS SCREWS REMOVAL Before removing the throttle stop screw or air screw record the number of
8. 15 10 15 ELECTRICAL EQUIPMENT SUPER9 50 STARTING SYSTEM Starter Button Stoplight 15 11 K KYM 15 ELECTRICAL EQUIPMENT SUPER9 50 STARTER RELAY INSPECTION Open the front tool box and remove the bolt Remove the front tool box 2 4 Disconnect the starter relay coupler and then remove the starter relay Connect the starter relay green yellow Red Yellow Red terminal to the 12V battery positive terminal and the relay yellow red terminal to the battery negative terminal Check for continuity between the starter relay red and red white terminals The relay is normal if there is continuity Red White Green Yellow STARTER MOTOR REMOVAL Bolts Disconnect the starter motor cable Remove the two bolts attaching the starter motor and remove the starter motor The installation sequence is the reverse of removal Starter Motor 15 ELECTRICAL EQUIPMENT STARTER MOTOR INSPECTION Starter Motor Connect a battery across the starter motor and check for its operation 1 Do not turn the starter motor for long time 2 This Inspection should be done with a fully charged battery Battery gt SUPER9 50 15 5 16 INSTRUMENT SWITCHES LIGHTS SUPER9 50 INSTRUMENT SWITCHES LIGHTS SERVICE INFORMATION TROUBLE
9. A Transmission Cover Install and tighten the transmission case cover bolts Install the clutch driven pulley 7 15 Install other removed parts in the reverse order of removal KYMCO 8 FINAL REDUCTION SUPER9 50 After installation fill the transmission case with the specified oil e Place the motorcycle on its main stand on level ground e Check the sealing washer for wear or damage Specified Gear Oil SAE90 Oil Capacity at disassembly 0 12 liter at change 0 1 liter Install and tighten the oil check bolt Torque 9 8 14 7N m Start the engine and check for oil leaks Check the oil level from the oil check bolt hole and add the specified ol to the proper level if the oil level is low Drain Bolt Oil Check Bolt Hole Filler KYMCO 9 GENERATOR SUPER9 50 A C GENERATOR SERVICE INFORMATION 9 1 GENERATOR 9 2 GENERATOR INSTALLATION eren 9 5 9 0 KYMCO 9 A C GENERATOR SUPER9 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e All A C generator maintenance and inspection can be made with the engine installed e Refer to Section 15 for A C generator inspection TORQUE VALUE Flywheel nut 34 3 39 2N m SPECIAL TOOLS Flywheel puller Universal holder KYMCO 9 A C GENERATOR SUPER9 50 SH10DA gt
10. Be careful not to damage the steering stem and front fork Bottom Cone Race 13 18 13 STEERING HANDLEBARFRONT WHEELFRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 BALL RACE REPLACEMENT Ball Race Remover Drive out the ball races Drive in new ball races gt Be sure to drive the ball races into place Outer Driver completely Top Cone Race INSTALLATION Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and 29 steel balls on the bottom ball race Then install the front fork Ball Race 13 19 13 STEERING HANDLEBAR FRONT WHEELFRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 Apply grease to the top cone race and install it Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely Check that the steering stem rotates freely without vertical play Install the steering stem lock nut and tighten Lock Nut Wrench Lock Nut Socket it while holding the top cone race Torque 78 4 117 6N m Install the front wheel c 13 7 Install the front brake caliper gt 13 12 Install the front inner fender 42 6 Install the throttle grip and the right and left handlebar switches gt 13 5 Install the right and left brake master cylinders gt 13 5 13 20 14 BRAKE REAR FORK REAR KYMCO __ WHEEL REAR SHOCK ABSORBER 5
11. Final reduction removal e Special tools must be used for crankshaft and crankcase assembly When separating the crankcase the bearing will remain in the crankcase and it should be removed When assembling drive a new bearing into the crankcase and install a new oil seal Standard mm Service Limit mm Connecting rod big end side clearance Connecting rod big end radial Crankshaft runout A B los 0 15 0 10 SPECIFICATIONS clearance SPECIAL TOOLS Crankcase puller Bearing outer driver handle A Universal bearing puller Bearing outer driver 42x47mm Crankcase assembly collar Bearing driver pilot 20mm Crankcase assembly tool Bearing outer driver 37x40mm Bearing driver pilot 17mm TROUBLESHOOTING Abnormal engine noise e Excessive crank journal bearing play e Excessive crankpin bearing play e Excessive transmission bearing play 10 1 KYMCO 10 CRANKCASE CRANKSHAFT SUPER9 50 CRANKCASE SEPARATION Remove the crankcase attaching bolts Attach the crankcase puller on the right Crankcase Puller crankcase and remove the right crankcase from the left crankcase CRANKSHAFT REMOVAL Crankcase Puller Attach the crankcase puller on the left crankcase and remove the crankshaft from the left crankcase When removing the crankshaft do it slowly and gently 10 2 KYMCO 10 CRANKCASE CRANKSHAFT SUPER9 50 Remove the remaining bearing on the crankshaft side using the un
12. TIRE SPECIFICATION Front 120 70 12 Rear 130 70 12 TORQUE VALUES Front axle nut 49 0 68 6N m Rear axle nut 107 8 127 4N m KYMCO 3 INSPECTION ADJUSTMENT SUPER9 50 INSPECTION AND MAINTENANCE SCHEDULE Note 1 means time for inspection 2 yxmeans regular replacement for the specified parts This inspection and maintenance schedule is based upon average riding conditions Machines subjected to serve use or ridden in unusually dusty areas require more frequent servicing Frequency Inspection amp Maintenance Item st Every 6 Every 12 Judement Standards Remarks rende month months months handlebar Check for front fork pivot installation Check front fork pivot for looseness and abnormal noise Standard Brake drum wear and Rear 110 mm damage Service Limits Rear 111 mm RES 1 1 75 2 25 rider kg cm kg cm Tire 120 70 130 70 Size 12 12 KYMCO 3 INSPECTION ADJUSTMENT SUPER9 50 Inspection amp Maintenance Item Judement Standards Remarks Tire crack and damage Groove Depth Tire groove and o o Erm Imbedded objects gravel etc Torque Values Front axle nut Axle nut looseness 49 0 68 6N m Rear axle nut 107 8 127 4N m Rim runout at rim end Check wheel rim rim Front Axial 2 0mm edge and spoke plate for Radial 2 0mm damage Rear Axial 2 0mm Radial 2 0mm Check front wheel bear ing for
13. t operate Weak dead battery Connect starter motor directly to gt battery Starter motor Starter motor o LOOSE turns slowly turns normally _ Faulty starter relay Rotate crankshaft gt Turns easily Hard to turn QO Seized cylinder Broken or shorted starter motor cable Faulty starter pinion 3 Starter motor does not stop turning Inspection Adjustment Symptom Probable Cause Turn ignition switch OFF Not stopped Stopped 0O Faulty starter pinion Starter relay shorted or stuck closed 1 34 KYMCO 2 EXHAUST MUFFLER FRAME COVERS SUPER9 50 EXHAUST MUFFLER FRAME COVERS SER VICE INFORMATION 254 TROUBLESHOOTING lt lt 21 FRAME COVERS REMOVAL 250 EXHAUST MUFFLER REMOVAL 2 6 2 0 KYMCO 2 EXHAUST MUFFLER FRAME COVERS SUPER9 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e When removing frame covers use care not to pull them by force because the cover joint claws may be damaged e Make sure to route cables and harnesses according to the Cable amp Harness Routing TORQUE VALUES Exhaust muffler lock bolt 34 3N m Exhaust muffler joint lock nut 11 8N m TROUBLESHOOTING Noisy exhaust muffler e Damaged exhaust muffler e Exhaust muffler joint air leaks Lack of power e Caved exhaust muffler e Clogged e
14. the brake arm onto the brake cam Align the punch mark on the brake arm with the scribed line on the brake cam Install and tighten the brake arm bolt Install the brake arm return spring Install the brake shoes Brake Arm 14 6 14 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER SUPER9 50 Brake Arm Brake Cable Install the brake arm pin Connect the brake cable and install the adjusting nut Install the rear wheel Adjust the rear brake lever free play 3 12 Adjusting Nut Brake Arm Pin REAR SHOCK ABSORBER Air Cleaner REMOVAL Remove the rear carrier and frame body cover 22 2 Remove the met in box 252 2 Remove the two air cleaner bolts Remove the rear shock absorber upper mount bolt Remove the left rear shock absorber upper and lower mount bolts Remove the left rear shock absorbers Lower Mount Bolts 14 7 14 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER SUPER 9 50 DISASSEMBLY Disassemble the left rear shock absorbers using the rear shock absorber remover Rear Shock Absorber Remover INSPECTION Inspect the damper rod for bending or damage Inspect the damper for oil leaks Inspect the damper rubber for deterioration or damage Damper Damper Rod Rubber Measure the front shock absorber spring free length Service Limit Left 226mm 14 8 14 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSOR
15. Engine Hood Installation Install the engine hood 6 3 Install the spark plug cap 6 3 Perform the following inspections after installation e Compression test e Abnormal engine noise e Cylinder air leaks Spark Plug Engine Hood KYMCO 6 CYLINDER HEAD CYLINDER PISTON SUPER9 50 CYLINDER PISTON CYLINDER REMOVAL Remove the met in box and seat Remove the frame body cover Remove the cylinder head 6 3 Remove the two exhaust muffler joint lock nuts and two exhaust muffler lock bolts Remove the exhaust muffler Remove the cylinder Remove the cylinder gasket gt Do not pry between the cylinder and crankcase or strike the fins PISTON REMOVAL Remove the piston pin clip to remove the piston pin and piston Exhaust Muffler Lock Bolts Joint Lock Nuts Piston Pin Piston e Do not damage or scratch the piston Do not apply side force to the connect ing rod when removing the piston pin e Place clean shop towels in the crank case to keep the piston pin clip from falling into the crankcase Piston Pin Clip Spread each piston ring and remove by lifting it up at a point just opposite the gap Remove the expander KYMCO 6 CYLINDER HEAD CYLINDER PISTON SUPER9 50 CYLINDER PISTON INSPECTION Check the cylinder and piston for wear or damage Clean carbon deposits from the exhaust port area gt Be careful not to damage the cylinder inside wall Measure
16. GENERAL INFORMATION SUPER9 50 FRAME ee eese Fus 3 C 29 ona os ELECTRICAL EQUIPMENT go current Secondary coil i ghition eot tresistanee auth plus cap 6 99 10 21 6 99 10 21 DURAN 3 24 396 3 24 396 Pulser coil resistance 20 80 160Q 80 160Q Ignition timing 13 5 42 BTDC 2000rpm 13 5 42 BTDC 2000rpm 1 13 KYMCO 1 GENERAL INFORMATION SUPER9 50 TORQUE VALUES ENGINE Thread dia mm Torque N m Cylinder head bolt BF7x115 14 7 16 7 Clutch drive plate nut 10 34 3 39 2 Clutch outer nut 10 34 3 44 Drive face nut NH12 49 0 58 8 Oil check bolt 10 9 8 14 7 Engine mounting bolt 10 95 44 1 53 9 Engine hanger bracket bolt 10 50 34 3 44 1 Exhaust muffler joint lock nut 9 8 13 7 Exhaust muffler lock bolt BF8x35 29 4 35 3 Spark plug 10 8 16 7 Thread dia mm Torque N m Handlebar lock nut 44 49 0 Flange bolt U nut Steering stem lock nut 78 4 117 6 Steering top cone race 4 9 12 7 Front axle nut 49 0 68 6 Flange U nut Rear axle nut 107 8 127 4 Flange U nut Rear brake arm bolt Flange nut Front shock absorber upper mount bolt 32 3 Flange bolt U nut lower mount bolt 32 3 Cross head hex bolt 14 7 29 4 Apply locking agent Front damper nut 14 7 29 4 Front pivot arm bolt Flange screw U nut Rear shock absorber upper mount
17. two exhaust muffler lock bolts Remove the bolt attaching the engine hood to remove the engine hood The installation sequence is the reverse of removal When installing the exhaust muffler first tighten the two nuts on the front and then tighten the two bolts Bolts Cylinder head Bolts Remove the spark plug Remove the cylinder head bolts and the cylinder head gt Loosen the bolts diagonally in 2 or 3 times Remove the cylinder head gasket 6 3 KYMCO 6 CYLINDER HEAD CYLINDER PISTON SUPER9 50 COMBUSTION CHAMBER Combustion Chamber DECABONIZING Remove the carbon deposits from the combustion chamber Avoid damaging the combustion cham ber wall and cylinder mating surface Mating Surface CYLINDER HEAD INSPECTION Check the cylinder head for warpage with a straight edge and feeler gauge Service Limit 0 10mm replace if over 5 0 10mm replace if over CYLINDER HEAD INSTALLATION Cylinder head Gasket Install the cylinder head on the cylinder properly gt Be careful not to damage the mating surfaces Install a new cylinder head gasket onto the cylinder KYMCO 6 CYLINDER HEAD CYLINDER PISTON SUPER9 50 Cylinder Head Bolts Installation Cylinder head Bolts Install and tighten the cylinder head bolts diagonally in 2 or 3 times Torque 14 7 16 66N m Install the spark plug Torque 10 78 16 66N m Spark Plug Cylinder Head
18. 2 Clogged carburetor 3 Carburetor adjusted improperly 3 Clogged air cleaner 4 Clogged air cleaner 4 Faulty spark plug 5 Faulty spark plug 5 Incorrect ignition timing 6 Incorrect ignition timing 17 1 17 EVAPORATIVE EXHAUST EMISSION CONTROL SYSTEM SUPER9 50 EXHAUST MUFFLER Exhaust Muffler Joint Lock Nut REMOVAL m Remove the two exhaust muffler joint lock nuts and two exhaust muffler lock bolts Remove the exhaust muffler e The temperature of exhaust muffler is very high careful to avoid burns during working Exhaust Muffler Lock Bolts INSPECTION 1 Inspect the exhaust muffler and joint for damage or crack Replace if necessary 2 Inspect the exhaust muffler joint packing collar for deformation or damage Replace if necessary INSTALLATION 1 Install the exhaust muffler in the reverse order of removal A large amount of unburned mixture flowing into the high heat catalytic converter will burn again and cause damage to the converter due to overheat Pay attention to the following Use 92 or 95 nonleaded gasoline only Leaded gasoline will cause catalytic converter failure During riding do not turn the ignition switch OFF to avoid a large amount of unburned mixture flowing into the exhaust muffler e Faulty ignition system or fuel system will cause overheat and damage to the catalytic converter 17 2 17 EVAPORATIVE EXHAUST EMI
19. 3 9 HEADLICH TAIM oases 3 10 COOLING 3 10 BRAKES Y TEN u 2 0 NUIS BOLTS BASTENERS o eet euet 3 13 WHEEES TIRES trece dee a STEERING HANDLEBAR SUSPENSION eessen 4213 LUBRICATION 3 14 3 0 KYMCO 3 INSPECTION ADJUSTMENT SUPER 9 50 SERVICE INFORMATION GENERAL WARNING eBefore running the engine make sure that the working area is well ventilated Never run the engine in a closed area The exhaust contains poisonous carbon monoxide gas which may cause death to people eGasoline is extremely flammable and is explosive under some conditions The working area must be well ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area SPECIFICATIONS ENGINE Throttle grip free play 2 6mm Spark plug NGK BR8HSA Spark plug gap 0 6 0 7mm Idle speed SH1ODA 2000 100rpm SF10DA 1900 100rpm Lubrication oil capacity Cylinder compression 11 842kg cm At disassembly 1 7 liter Ignition timing BTDC 13 59 22 2000 At change 1 4 liter Coolant capacity 1165cc Gear oil capacity Radiator capacity 825cc At disassembly 0 12 Reserve tank capacity 340 At change 0 10 liter CHASSIS Front rear brake free play 20 30mm TIRE 2 00kg cm 2 25kg cm
20. 4 KYMCO 6 CYLINDER HEAD CYLINDER PISTON SUPER 9 50 CYLINDER HEAD CYLINDER PISTON SERVICE INFORMATION 6 1 TROUBLESHOOTING Su a 6 1 CYLINDER HEAD a ege eo ie aho 6 2 CYLINDER PISTON EEN 6 6 6 0 KYMCO 6 CYLINDER HEAD CYLINDER PISTON SUPER9 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e The cylinder head cylinder and piston can be serviced with the engine installed in the frame e Before disassembly clean the engine to prevent dust from entering the engine e Remove all gasket material from the mating surfaces e Do not use a driver to pry between the cylinder and cylinder head cylinder and crankcase e Do not damage the cylinder inside and the piston surface e After disassembly clean the removed parts before inspection When assembling apply the specified engine oil to movable parts Cylinder head warpage Tt TORQUE VALUES Cylinder head bolt 14 7 16 66N m Exhaust muffler joint lock nut 9 8 13 72N m Exhaust muffler lock bolt 29 4 35 28N m Spark plug 10 78 16 66N m TROUBLESHOOTING Compression too low hard starting or poor performance at low speed Abnormal noisy piston e Leaking cylinder head gasket e Worn cylinder and piston e Loose spark plug e Worn piston pin or piston pin hole e Worn stuck or broken piston and piston rings Worn connecting rod small end
21. Clogged Not clogged Broken or shorted high tension wire 6 Faulty ignition switch mO Broken auto bystarter wire 2 Faulty auto bystarter 1 28 KYMCO 1 GENERAL INFORMATION SUPER9 50 POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Symptom Probable Cause Check ignition timing gt Faulty CDI unit Correct timing Incorrect timing Loose A C G stator Q Faulty A C generator Check auto fuel valve for fuel supply i Empty fuel tank Fuel flows freely Fuel flow restricted Q Clogged fuel tube or filter Clogged charcoal canister Check carburetor jets for clogging Not Clogged 0O Clean and unclog ga Remove auto bystarter connecting wire and check if bypass fuel line is clogged Not cl Clogged Broken auto bystarter wire 0 Faulty auto bystarter 09 gq Connect auto bystarter wire to battery Wat for 5 minutes then connect a hose to fuel enriching circuit and then blow the hose with mouth Clogged Not clogged Faulty auto bystarter be 1 29 1 GENERAL INFORMATION KYMCO SUPER9 50 CLUTCH DRIVE AND DRIVEN PULLEYS
22. E014 Driven pulley bearing installation 1 15 KYMCO 1 GENERAL INFORMATION SUPER9 50 LUBRICATION POINTS ENGINE Crankcase sliding amp movable JASO FC or API TC 1 2 Cylinder movable parts pn pei 3 Transmission gear final gear SAE 90 am 4 Kick starter spindle bushing Grease j 5 Drive pulley movable parts Grease 6 Starter pinion movable parts Greases o O 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 22 Grease RU Engine Front Rear Brake Lever Throttle Cable AEN Grease S Seat Lock Engine Oil Speedometer Cable tf Grease Speedometer Gear Brake Cam Front Shock Absorber Lower Mount Bushings Pivot MEN Grease Rear Wheel Bearing Grease H Main Stand Pivot Rear Brake Cable 1 16 KYMCO 1 GENERAL INFORMATION SUPER9 50 Brake Master Cylinders Rear Stop Front Stop Switch Switch Throttle Cable Speedometer Cable Water Hose Horn Reserve Cap Resistors Wire Harness Radiator 1 17 KYMCO 1 GENERAL INFORMATION SUPER9 50 Winker Ignition Switch Regulator Rectifier Water Hose Fuse Box CDI Unit Front Brake Fluid Tube Starter Relay 1 18 KYMCO 1 GENERAL INFORMATION SUPER9 50 Throttle Cable Reserve Cap Water Hose Speedometer Cable Wire H
23. Faulty oil meter Motor oil indicator light winks e Loose wire connection e Broken wire e Faulty oil meter Fuel gauge pointer does not register correctly e Disconnected wire or connector e Broken wire e Faulty float e Faulty fuel unit e Faulty instrument Fuel gauge pointer fluctuates or swings e Loose wire connection e Faulty fuel unit e Faulty instrument 16 INSTRUMENT SWITCHES LIGHTS SUPER9 50 FUEL UNIT Fuel Unit REMOVAL Remove the frame body cover 42 3 Disconnect the fuel unit wire connectors Turn the fuel unit retainer counterclockwise to remove it Do not damage the fuel unit wire Remove the fuel unit careful not bend or damage the fuel unit float arm INSPECTION Remove the fuel unit Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions 530 FUEL GAUGE INSPECTION Connect the fuel unit wire connectors and turn the ignition switch ON Before performing the following test operate the turn signals to determine that the battery circuit is normal Check the fuel gauge needle for correct indication by moving the fuel unit float up and down F Fal E Empo 16 2 16 INSTRUMENT SWITCHES LIGHTS SUPER9 50 INSTALLATION Tab The installation sequence is the reverse of removal e Align the tab on the fuel unit with the groove on the fuel tank e Turn t
24. Make sure that sealing washer 5 good condition Fill the final reduction with the recommended oil SAE90 Gear Oil Capacity At disassembly 120cc At change 100cc Reinstall the oil check bolt and check for oil 1 DRIVE BELT Remove the left crankcase cover Inspect the drive belt for cracks or excessive wear Replace the drive belt with a new one if necessary and in accordance with the Maintenance Schedule Drive Belt 3 INSPECTION ADJUSTMENT KYMCO 9 50 HEADLIGHT AIM Turn the ignition switch ON Turn on the headlight switch Adjust the headlight aim by turning the headlight aim adjusting bolt COOLING SYSTEM COOLANT LEVEL INSPECTION Place the motorcycle on its main stand on level ground Check the coolant level of the reserve tank and the level should be between the upper and lower level lines If necessary fill the reserve tank with recommended coolant to the level line Recommended Coolant SIGMA Coolant Standard Concentration 30 gt e The coolant level does not change no matter the engine is warm or cold to the F upper line COOLANT REPLACEMENT Perform this operation when the engine 15 cold Remove the front cover Remove the reserve cap Remove the drain hoses to drain the coolant and tilt the motorcycle to the right and the coolant will drain more easily Drain the co
25. bolt 34 3 44 1 Flange nut lower mount bolt 23 5 29 4 lower Joint nut 14 7 24 5 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 Torque N m Torque N m 5mm bolt nut 44 59 5mm screw 3 43 4 9 6mm bolt nut 7 8 11 8 6mm screw SH bolt 6 86 10 8 8mm bolt nut 17 6 24 5 6mm flange bolt nut 9 8 13 7 10mm bolt nut 29 4 39 2 8mm flange bolt nut 23 5 29 4 12mm bolt nut 49 0 58 8 10mm flange bolt nut 14 7 44 1 1 14 KYMCO 1 GENERAL INFORMATION SUPER9 50 SPECIAL TOOLS Universal bearing puller E030 Crankshaft bearing removal Lock nut socket wrench 001 holding F001 Stem lock nut tightening Crankcase puller E026 Crankcase disassembly Bearing remover set 12mm Drive shaft bearing removal installation Spindle assy 15mm Remover weight Bearing remover set 15mm Drive shaft bearing removal installation Spindle assy 15mm Remover head 15mm Remover shaft 15mm Bearing outer driver 28x30mm E014 Bearing installation Clutch spring compressor E027 Driven pulley disassembly assembly Drive shaft bearing installation Bearing outer driver 32x35mm P014 Final shaft bearing installation Drive shaft bearing installation Final Bearing outer driver 37x40mm E014 shaft bearing installation Crankshaft bearing installation Outer driver 24x26mm
26. driven face spring e Worn or damaged clutch lining e Worn weight roller e Faulty driven face Engine stalls or motorcycle creeps e Broken clutch weight spring 7 1 7 KICK STARTER DRIVE PULLEY CO KYMCO CLUTCH DRIVEN PULLEY GUPERS 5 KICK STARTER LEFT CRANKCASE COVER REMOVAL Remove the drive belt cooling air tube connector circlip Remove the nine left crankcase cover bolts left crankcase cover and dowel pins Inspect the left crankcase cover seal rubber for damage or deterioration KICK STARTER SPINDLE REMOVAL Remove the Kick lever from the kick starter spindle Remove the circlip and washer from the kick starter spindle Kick Starter Spindle Washer Circlip Slightly rotate the kick starter spindle to remove the kick starter driven gear together with the friction spring Friction Spring Kick Starter Driven Gear 7 2 7 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY SUPER 0 S0 Remove the kick starter spindle and return Kick Starter Spindle spring from the left crankcase cover Remove the kick starter spindle bushing Return Spring KICK STARTER SPINDLE INSPECTION Spindle Return Spring Inspect the kick starter spindle and gear for wear or damage Inspect the return spring for weakness or damage Inspect the kick starter spindle bushing for wear or damage L Yoo Plastic Bushing Spindle Bushing Check the kick starter driven gear for wear Frictio
27. excessive play and abnormal noise Check front wheel bear ing for excessive play and abnormal noise spring free length Suspen Connecting parts loose sion arm ness arm damage 9 Assembly parts loose ness abnormal noise pum ewe Ioue e Oil level Rear wheel sion leakage and oil level Oil check bolt hole transmis at lower hole edge sion case 2 Spark plug condition s em gap 0 6 0 7mm pamore L Loose connection and Wires damage KYMCO 3 INSPECTION ADJUSTMENT SUPER9 50 Frequency Inspection amp Maintenance Item Is Every 6 2 Judgment Standards Remarks Preride month months months Air cleaner Oil level indicator Oil quality and quantity Indicator light comes on Lubrica when oil is insufficient Engine en yore Oil evel O Check oil filter for clogging Of J Fuel leakage EE 4 Carburetor throttle valve and O Fuel auto bystarter System Check fuel filter for clogging Fuel evel FEE IN CE ERN Fusl pM Operation Winker Winking action dirt and damage Buzzer amp Operation Steering Lock P Rearview Mirror Rearvi iti Rearview amp Reflector earview mirror position Performance abnormal Conditions at low high Body speeds Exhaust smoke R
28. flywheel onto the crankshaft with the flywheel groove aligned with the crankshaft woodruff key Hold the flywheel with the universal holder and install the flywheel flange nut Torque 34 3 39 23 Start the engine and check the ignition timing 53 7 Install other removed parts in the reserve order of removal KYMCO 10 CRANKCASE CRANKSHAFT SUPER9 50 CRANKCASE CRANKSHAFT SERVICE INFORMATION TROUBLESHOOTING CRANKCASE SEPARATION CRANKSHAFT REMOVAL CRANKSHAFT INSPECTION CRANKCASE ASSEMBLY 10 0 KYMCO 10 CRANKCASE CRANKSHAFT SUPER9 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e This section covers crankcase separation to service the crankshaft e The following parts must be removed before separating the crankcase Engine gt Section 5 Driven pulley gt Section 7 Carburetor gt Section 12 A C generator gt Section9 Oil pump Section 4 Cylinder head cylinder gt Section 6 Reed valve gt Section 12 e When the left crankcase must be replaced remove the following part in addition to the above
29. front rear shock absorbers by compressing them several times Check the entire shock absorber assembly for oil leaks looseness or damage Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn Replace the engine hanger bushings if there is any looseness 3 13 KYMCO 3 IISPECTION ADJUSTMENT SUPER9 50 LUBRICATION SYSTEM Oil Filter Cleaning Disconnect the oil tube at the oil pump side and allow oil to drain into a clean container Remove the tube clip at the oil tank side and disconnect the oil tube Remove the oil filter Clean the oil filter screen with compressed air Install the oil filter in the reverse order of removal and fill the oil tank with specified oil up to the proper level Bleed air from the oil pump and oil lines e Connect the oil tubes securely Oil Filter clip Install the tube clip at the oil tank side and also install the clip to the lower oil tube that goes to the oil pump e Check for oil leaks Pump Condition Adjust oil pump control cable after the throttle grip free play is adjusted Open the throttle valve fully and check that the index mark on the pump body aligns with the aligning mark on the oil pump control lever Reference tip alignment within 1mm of index mark on open side is acceptable Start and idle the engine then slowly open the throttle to increase engine rpm and check the
30. of the oil seal and then install it 10 5 Bearing Outer Driver Handle A Bearing Outer Driver 37x40mm Bearing Driver Pilot 17mm Bearing Outer Driver Handle A 1 Bearing Outer Driver 42x47mm Pilot 20mm Crankcase Assembly Tool Crankcase Assembly Collar KYMCO 10 CRANKCASE CRANKSHAFT SUPER9 50 CRANKCASE ASSEMBLY Dowel Pins Install the dowel pins and a new gasket to the crankcase mating surface Assemble the crankcase halves The distance between the right crankcase oil seal and crankcase surface is about 12 5 0 5 mm 0 When installing the oil seal be careful to press it with even force Crankcase Oil Seal 10 6 KYMCO 10 CRANKCASE CRANKSHAFT SUPER9 50 The distance between the left crankcase seal and crankcase surface 15 about 1 0mm Oil Seal Install and tighten the crankcase attaching bolts After assembly check the crankshaft for smooth operation 10 7 11 COOLING S KYMCO YSTEM SUPER9 50 COOLING SYSTEM SERVICE INFORMA TION us etie e TROUBLESHOOTING 11 1 RADIATORE 11 3 WATER PUMP 23235 eet ete 11 6 e 11 12 EIERE 11 13 11 0 KYMCO 11 COOLING SYSTEM SUPER9 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e The water pump must be serviced after removing the engine O
31. operation of the oil pump control lever If adjustment is necessary adjust the oil pump control cable by loosening the control cable lock nut and turning the adjusting nut After adjustment tighten the lock nut Filter Screen Reference tip alignment within 1mm of index mark on open side is acceptable However the aligning mark on the control lever must never be on the closed side of the index mark otherwise engine damage will occur because of insufficient lubrication If the oil pump is not synchronized properly the following will occur e Excessive white smoke or hard starting due to pump control lever excessively open eSeized piston due to pump control lever Adjusting Nut Pump Body Index Mark insufficiently open KYMCO 4 LUBRICATION SYSTEM SUPER9 50 LUBRICATION SYSTEM SERVICE INFORMATION 4 1 4 1 OIL D EE E E 4 2 OIL PUMP INSPECTION 4 2 OIL PUMP INSTALLATION eege 4 3 OIL PUMP EE 4 4 OTE TANE dp aito 4 5 4 0 KYMCO 4 LUBRICATION SYSTEM SUPER9 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e Use care when removing and installing the oil pump not to allow dust and dirt to enter the engine and oil line e Do not attempt to disassemble the oil pump e Bleed air from the oil pump if there is air between the oil pump and oil line e If the oil is disconnected refill t
32. rotations until it seats lightly Then remove them gt Do not force the air screw against its seat to prevent damage Remove the main jet and needle jet holder Main Jet Throttle Stop Screw Air Screw CARBURETOR PASSAGES CLEANING Blow compressed air through all passages of the carburetor body with an air gun 12 8 KYMCO 12 CARBURETOR SUPER9 50 FLOAT CHAMBER ASSEMBLY Needle Jet holder Main Jet Install the main jet and needle jet holder Install the air screw and throttle stop screw according to the rotations recorded If the air screw must be replaced be sure to perform the air screw adjustment again Throttle Stop Screw Air Screw Install the float valve float and float pin Tighten the float screw securely Float Pin FLOAT LEVEL INSPECTION Slightly tilt the carburetor and measure the float level with the float valve just connecting the float arm Float Level 8 6 mm Replace the float if the level is out of the specified level range Install the O ring Check the operation of the float and install the float chamber Tighten the screws 12 9 KYMCO 12 CARBURETOR SUPER9 50 CARBURETOR INSTALLATION O rings gt When installation do not allow foreign particles to enter the carburetor Check the carburetor insulator and O ring for wear or damage Install the carburetor and insulator onto the intake manifold and tighten the two lock nuts Connect th
33. the exhaust muffler joint lock nuts Torque 9 8 13 72N m Tighten the exhaust muffler lock bolts Torque 29 4 35 28N m Install the frame covers 6 10 7 KICK STARTER DRIVE PULLEY C KYMCO CLUTCH DRIVEN PULLEY SUPER9 50 KICK STARTER DRIVE PULLEY CLUTCH DRIVEN PULLEY SERVICE INFORMATION TROUBLESHOOTING KICK STARTER DRIVE IS Bde DRIVE PULLEY tero ee eaten tora en eo EM KL STARTER PINION opor en edid CLUTCH DRIVEN PULLEY DOTTER nr oeeoo 7 0 7 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY SUPERO SERVICE INFORMATION GENERAL INSTRUCTIONS e Avoid getting grease and oil on the drive belt and pulley faces VALUES Drive face nut 34 3 39 2N m Clutch outer nut 34 3 44 1N m Clutch drive plate nut 49 0 58 8N m SPECIAL TOOLS Lock nut wrench 28mm Universal holder Clutch spring compressor Lock nut socket wrench 32mm Bearing outer driver 37x40mm Bearing driver pilot 17mm One way clutch puller Outer driver 24x26mm TROUBLESHOOTING Poor performance at high speed or Engine starts but motorcycle won t move lack of power e Worn drive belt e Worn drive belt e Broken ramp plate e Weak
34. the cylinder bore at three levels of and C both X and Y directions Avoid port area Take the maximum figure measured to determine the cylinder bore Service Limit 39 05mm replace if over SF10DA 39 05mm replace if over Inspect the top of the cylinder for warpage Service Limit 0 10mm replace if over SF10DA 0 10mm replace if over KYMCO 6 CYLINDER HEAD CYLINDER PISTON SUPER9 50 The cylinder has mark or mark onit When replacing the cylinder with a new one use a cylinder having the same mark as the old one A Mark Measure the piston O D at a point 5mm from the bottom of the piston skirt Service Limit 38 90mm replace if below SF10DA 38 90mm replace if below Measure the piston to cylinder clearance Service Limit SHIODA 0 10mm replace if over SF10DA 0 10mm replace if over Measure the piston pin hole I D Service Limit SHIODA 12 03mm replace if over SFIODA 12 03mm replace if over Measure the piston pin O D Service Limit SHIODA 11 98mm replace if below SF10DA 11 98mm replace if below Measure the piston to piston pin clearance Service Limit SHIODA 0 03mm replace if over SF10DA 0 03mm replace if over 6 CYLINDER HEAD CYLINDER PISTON PISTON RING INSPECTION Eecler Gauge Measure each piston ring end gap Service Limits Top Second SHIODA 0 40mm replace if over SF10DA 0 40mm rep
35. the driven face Then Install the guide roller pins O rings and a new oll seal O rings Guide Roller Pin Install the seal collar Seal Collar 7 15 7 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY SUPER S EO Set the driven pulley driven face spring and clutch assembly onto the clutch spring compressor Compress the tool and install the 28mm drive plate nut Tighten the 28mm nut to the specified torque Torque 49 0 58 8N m CLUTCH DRIVEN PULLEY INSTALLATION Install the drive belt on the clutch driven pulley and then install the clutch driven pulley onto the drive shaft Install the clutch outer Hold the clutch outer with the universal holder Install and tighten the 10mm clutch outer nut Torque 34 3 44 1N m Install the left crankcase cover 7 5 Universal Holder KYMCO 8 FINAL REDUCTION SUPER9 50 FINAL REDUCTION SERVICE INFORMATION 8 1 TROUBLESHOOTING 8 1 FINAL REDUCTION DISASSEMBLY 8 2 FINAL REDUCTION INSPECTION 8 2 FINAL REDUCTION ASSEMBLY mmm mne 8 5 8 0 KYMCO 8 FINAL REDUCTION SUPER9 50 SERVICE INFORMATION Specified Oil SAE90 At disassembly 0 12 liter At change 0 1 liter SPECIAL TOOLS Bearing re
36. 00rpm IMAA 8 Mar eco Deh Rear clearance cold Shock absorber Idle speed rpm 1900 100rpm Double swing q Separate E Plunger type Full flow filtration Air cooling KYMCO 1 GENERAL INFORMATION SUPER9 50 SERVICE PRECAUTIONS Make sure to install new gaskets O rings circlips cotter pins etc when reassembling B 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 B 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 1 4 1 GENERAL INFORMATION E Apply or add designated greases and lubricants to the specified lubrication points After reassembly check all parts for proper tightening and operation E When two persons work together attention to the mutual working safety B Disconnect the battery negative terminal before operation B When using a spanner or other tools make sure not to damage the motorcycle surface B After operation check all connecting points fasteners and lines for proper connection and installation E When connecting the battery the positive terminal must be connected first B After connection apply grease t
37. 3 KYMCO 2 EXHAUST MUFFLER FRAME COVERS SUPER9 50 LEG SHIELD REMOVAL Ignition Switch Remove the front upper cover Remove the front lower cover Disconnect the leg shield and ignition switch cover Remove the two bolts attaching the leg shield Bolts Remove the leg shield The installation sequence is the reverse of removal Leg Shield Front Tool Box FRONT TOOL BOX REMOVAL Open the front tool box and remove the Remove the front tool box KYMCO 2 EXHAUST MUFFLER FRAME COVERS SUPER9 50 Remove the center cover by pulling them backward Remove the center cover Center Cover FLOOR BOARD REMOVAL Remove the screw and two bolts attaching the front right and left side covers Remove the two bottom cover attaching screws Screws Screws Remove the four bolts attaching the floor Floor Board board Remove the floor board The installation sequence is the reverse of removal 2 5 2 EXHAUST MUFFLER FRAME COVERS KYMCO SUPER9 50 BOTTOM COVER REMOVAL Remove the four screws attaching the bottom cover and inner bottom cover Remove the bottom cover FRONT INNER FENDER REMOVAL Remove front upper cover 42 3 Remove the front lower cover 2 3 Remove the leg shield and floor board Remove the bottom cover Remove the screws which combines front fender and the front axle nut to pull out the axle Remove the front fender and the front wheel and th
38. A C GENERATOR REMOVAL Disconnect the water hoses from the right crankcase cover Remove the three bolts attaching the right crankcase cover and the cover Hold the flywheel with an universal holder and then remove the flywheel nut Universal Holder 9 A C GENERATOR SF10DA gt A C GENERATOR REMOVAL Remove the three bolts attaching the fan cover to remove the fan cover Remove the cooling fan by removing the four bolts Hold the flywheel with an universal holder and then remove the flywheel nut Universal Holder KYMCO SUPER9 50 KYMCO 9 A C GENERATOR SUPER9 50 Remove the A C generator flywheel using the flywheel puller Flywheel Puller Remove the A C generator wire connector A C Generator Wire Connector Remove the two pulser coil bolts and pulser coil from the right crankcase Remove the pulser coil wire clamp from the right crankcase Remove the two bolts attaching the A C generator stator gt Be careful not to damage the discon nected wire Pulser Coil KYMCO 9 GENERATOR SUPER9 50 Generator Wire Connector GENERATOR INSTALLATION Install the A C generator stator and pulser coil wire clamp onto the right crankcase and then install the pulser coil Connect the A C generator wire connector Clean the taper hole in the flywheel off any burrs and dirt Install the woodruff key in the crankshaft keyway Install the
39. ANTI RUST AND ANTI FREEZING EFFECTS 9c 20 17 32356 j 1 ee C a 7 V j mse 35 Cautions for Using Coolant e Use coolant of specified mixing rate The mixing rate of 360cc KYMCO SIGMA coolant concentrate 825cc distilled water is 30 e Do not mix coolant concentrate of different brands e Do not drink the coolant which is poisonous e The freezing point of coolant mixture shall be 5 C lower than the freezing point of the riding area 11 2 KYMCO 11 COOLING SYSTEM SUPER9 50 RADIATOR Front Upper Cover RADIATOR INSPECTION Remove the front upper cover 42 3 Remove the front lower cover 2 3 Inspect the radiator soldered joints and Radiator seams for leaks Blow dirt out from between core fins with 4 compressed air If insects etc are clogging radiator wash them off Emma Carefully straighten bent fins d RADIATOR REMOVAL Upper Hose Drain the coolant 3 10 Loosen the hose band and disconnect the upper and lower hose from connect the radiator and reserve tank Lower Hose Reserve Tank 11 3 11 COOLING SYSTEM Loosen the hose band and disconnect the upper hose from the radiator Loosen the hose band and disconnect the lower hose from the radiator Remove the two bolts and the radiator Upper Hose KYMCO 9 50 Radiator Radiator 11 COOLING SYSTEM RADIATOR BRAC
40. After clamping check each wire to make sure it is secure X Q d E Do not squeeze wires against the weld or its clamp QR After clamping check each harness to make sure that it is not interfering with 2 L t any moving or sliding parts Moers E B 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 1 8 KYMCO 1 GENERAL INFORMATION SUPER9 50 Route harnesses so they are neither pulled tight nor have excessive slack des Ex tight E Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner B When rubber protecting cover is used to O X protect the wire harnesses it shall be installed securely B Do not break the sheath of wire E If a wire or harness is with a broken sheath repair by wrapping it with protective tape or replace it B When installing other parts do not press or squeeze the wires Do not press or squeeze the wire 1 9 1 GENERAL INFORMATION After routing check that the wire harnesses are not twisted or kinked E Wire harnesses routed along with handlebar should not be pulled tight have excessive slack or interfere wi
41. BER SUPER9 50 ASSEMBLY Assemble the rear shock absorbers in the reverse order of disassembly INSTALLATION Install the rear shock absorbers in the reverse order of removal Torque Upper Mount Bolt 39 2N m Lower Mount Bolt 19 6 29 4N m Lower Mount Bolts 14 9 K KYM 15 ELECTRICAL EQUIPMENT SUPER9 50 ELECTRICAL EQUIPMENT SERVICE INFORMATION EE 15 1 TROUBLESHOOTING un lu 15 1 CHARGING SYSTEM eet 15 3 15 4 IGNITION SY STEM 15 7 STARTING SYSTEM E 15 11 15 0 15 ELECTRICAL EQUIPMENT SUPER9 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e It is not necessary to check the battery electrolyte or fill with distilled water e Remove the battery from the motorcycle for charging Do not remove the electrolyte cap e Do not quick charge the battery Quick charging should only be done in an emergency e Charge the battery according to the charging current and time specified on the battery e When charging check the voltage open voltage with an electric tester e When replacing the battery do not use a traditional battery SPECIFICATIONS Primary coi Secondary cll 3 24 396 3 24 396 Pulser resistance 20 80 160Q 80 160Q Ignition timing 13 5 2 BTDC 1800rpm 13 5 2 BTDC 2000rpm TROUBLESHOOTING CHARGING SYSTEM No power Intermittent p
42. EPLACEMENT Remove the front wheel bearings and distance collar Special Tools Bearing Remover Bearing Remover Head 12mm 13 6 13 STEERING HANDLEBARFRONT WHEELFRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 Pack all bearing cavities with grease Driver Handle Drive in the left bearing Install the distance collar Drive in the right bearing e Do not allow bearings to tilt while driving them in e Drive in the bearing squarely with the sealed end facing out Special Tools Outer driver Driver handle Outer Driver INSTALLATION Speedometer Gear Unit Apply grease to the speedometer gear unit Install the speedometer gear unit by aligning its retaining pawl with the hub cutout If not aligned the retaining pawl will be deformed when the axle nut is tightened e After installing the axle turn the wheel to make sure that the speedometer drive shaft rotates freely Hub Cutout Pawl Install the front wheel by aligning the Tab speedometer gear unit groove with the front shock absorber tab Insert the axle and tighten the axle nut When installing the front wheel position the brake disk between the two brake pads Torque 44 1 49 0N m Groove Speedometer Gear Unit 13 7 13 STEERING HANDLEBARFRONT WHEELFRONT KYMCO BRAKE FRONTSHOCK ABSORBER FRONT FORK SUPER 9 50 FRONT BRAKE Holder Bolts BRAKE MASTER CYLINDER REMOVAL Remove the handle
43. KET REMOVAL INSTALLATION Remove the two nuts to remove the radiator bracket The installation sequence is the reverse of removal RADIATOR INSTALLATION Install the radiator on the radiator bracket with the two bolts Connect the upper and lower hoses and secure them with hose bands 11 5 Radiator Bracket Radiator KYMCO SUPER9 50 Nuts Lower Hoses KYMCO 11 COOLING SYSTEM SUPER9 50 Reinstall the upper and lower hoses make sure the bands are secured AA Genee Reserve Tank Lower Hose Fill the reserve tank with coolant 43 10 Air Duct Reserve Tank Check for coolant leaks Install the front upper and lower cover WATER PUMP MECHANICAL SEAL WATER SEAL INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage If the mechanical seal is leaking remove the right crankcase cover and replace the mechanical seal gt gt Telltale Hole Right Crankcase Cover 11 6 KYMCO 11 COOLING SYSTEM SUPER9 50 WATER PUMP IMPELLER REMOVAL Remove the engine from frame 45 2 Remove the three bolts and the water pump Bolts cover gasket and two dowel pins Water Pump Cover Remove the water pump impeller impeller has left hand threads Impeller 11 7 KYMCO 11 COOLING SYSTEM SUPER9 50 Inspect the mechanical water seal and seal Mechanical Seal Seal Washer Porcelain washe
44. NE REMOVAL INSTALLATION SUPER9 50 Remove the two bolts attaching the air cleaner case Loosen the band between the air cleaner and carburetor to remove the air cleaner case Remove the carburetor cap Remove the rear shock absorber lower mount bolt Carburetor Cap Band Air Cleaner Case Rear Shock Absorber Lower Mount Bolt Remove the right and left engine mounting nuts Take out the right and left engine mounting bolts Lift the frame upward to separate it from the engine and be careful not to damage Engine Mounting Nuts ENGINE HANGER BRACKET REMOVAL 3 Remove the engine hanger bracket bolt and engine hanger bracket The installation sequence is the reserve of removal Torque 44 1 53 9N m Engine Hanger Bracket Bolt KYMCO 5 ENGINE REMOVAL INSTALLATION SUPER9 50 ENGINE HANGER BRACKET Engine Hanger INSPECTION Inspect the stopper rubbers and bushings for damage and replace with new ones if necessary Bushings Stopper Rubbers ENGINE INSTALLATION Install the engine in the reverse order of removal Cables and wires should be routed properly Torque Values Engine mounting bolt 44 1 53 9N m Rear shock absorber lower mount bolt 23 5 29 4N m Perform the following inspections and adjustments after installation e Throttle cable Oil pump control cable 54 2 Rear brake system 3 11 Oil pump bleeding c4
45. NH WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ELECTRICAL EQUIPMENT ELECTRICAL EQUIPMENT INSTRUMENT SWITCHES LIGHTS aaa EMISSION CONTROL SYSTEM SISSVHO LNAWdINOA WA KYMCO 1 GENERAL INFORMATION SUPER9 50 GENERAL INFORMATION ENGINE SERIAL NUMBER 1 1 SPECIFICATIONS enii ee eo 1 9 SERVICE PRECAUTIONS 1 4 TOROUE V 1 14 SPECIAL TOOLS 1 15 LUBRICATION POINTS Ee 1 16 WIRING DIAGRAM 1 22 TROUBLESHOOTING e t 1 24 KYMCO 1 GENERAL INFORMATION SUPER9 50 ENGINE SERIAL NUMBER 4 Location of Engine Serial Number Location of Frame Serial Number 1 1 KYMCO 1 GENERAL INFORMATION SUPER9 50 SPECIFICATIONS Q PB s Displacement 49 4cc Fuel Used 3 5 22 J2000mpm EE Spark plu NGK urojs g ond J032Jnq Ie pomnog uonius 3 Tires Front wheel 120 70 12 Spark plug gap 0 6 0 7mm 130 70 12 12V4AH Perform Braking distance m 4 4m 30km HV ance 2150mm Gg Starting motor amp tarting system kick starter Gasoline 2 stroke Dry multi disc clutch Operation Aut
46. O ring e Damage to crankcase mating surface e Damage to pump body Control lever operation e Oil leaks through oil seals e Worn or damaged pump pinion 0 not disassemble oil pump which cannot be used after disassembly Control Lever Pinion 4 2 KYMCO 4 LUBRICATION SYSTEM SUPER9 50 OIL PUMP INSTALLATION Lubricate the O ring with grease engine oil before installation Make sure that the ol pump is inserted into the crankcase e Apply molybdenum disulfide or grease to the pump pinion Grease or Engine Oil Install the oil pump onto the crankcase Control Cable Plate Bolt Install the pump control cable plate Connect the oil inlet line and oil outlet line properly Connect the oil pump control cable Bleed air from the oil pump Oil Outlet Line 4 3 KYMCO 4 LUBRICATION SYSTEM SUPER9 50 OIL PUMP BLEEDING Oil Pump Oil Outlet Line e Air in the oil lines will block oil flow and result in severe engine damage e Bleed air from the oil lines and oil pump whenever the oil lines or pump have been removed or there is air in the oil lines Intake Manifold OIL INLET LINE OIL PUMP BLEEDING Fill the oil tank with recommended oil Place a shop towel around the oil pump Disconnect the oil inlet line from the oil pump and clip it Fill the oil pump with oil by squirting clean oil through the joint About 3cc Fill the oil line with oil and conne
47. OR 5 0 12 1 TROUBLESHOOTING enee uu saus 12 1 THROTTLE VALVE DISASSEMBL Y 12 2 THROTTLE VALVEINSTALLATION 12 3 CARBURETOR REMOVAL 12 4 AUTO BY S CAR PER ERE va 12 5 EEOATCHANIBER 12 7 FLOAT LEVEL INSPECTION 12 9 CARBURETOR INSTALLATION 12 10 AIR SCREW 12 10 PEED 12 11 12 0 KYMCO 12 CARBURETOR SUPER9 50 SERVICE INFORMATION GENERAL INSTRUCTIONS e When working with gasoline keep away from sparks and flames Note the locations of O rings when disassembling and replace them with new ones during assembly cables fuel lines and wires must be routed and secured at correct locations Bleed air from the oil lines whenever they are disconnected SPECIFICATIONS SHIODA SF10DA Identification number PB093 C PB058 C Float level 8 6mm Main Jet Unlimited limited speed 92 78 35 Idle speed 2000 100rpm 1900 100 Throttle grip free play SPECIAL TOOL Float level gauge TROUBLESHOOTING Engine does not start Lean mixture No fuel in tank Clogged fuel jets e Faulty float
48. RONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 Remove the piston from the brake caliper If necessary use compressed air to squeeze k out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratches or wear and replace if necessary Compressed Air Push the piston oil seal outward to remove it Clean the oil seal groove with brake fluid Be careful not to damage the piston surface Piston Oil Seal Check the piston for scratches or wear Measure the piston O D with a micrometer gauge Service Limit 25 30mm 13 12 13 STEERING HANDLEBARFRONT WHEELFRONT O KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 Check the caliper cylinder for scratches or wear and measure the cylinder bore Service Limit 25 45mm ASSEMBLY Clean all removed parts Apply silicon grease to the piston and oil seal Lubricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved side facing out Install the piston with its outer protruding 3 5mm beyond the brake caliper Wipe off excessive brake fluid with a clean shop towel Apply silicon grease to the brake caliper seat pin and caliper inside Install the brake caliper seat INSTALLATION Install the brake caliper to the shock absorber and tighten the two bo
49. Ratchet UNN ST wd Hold the drive pulley with the holder pu e remove the 17mm drive face nut Remove the starting ratchet 17mm washer and drive pulley face MOVABLE DRIVE FACE DISASSEMBLY Remove the movable drive face and drive pulley collar from the crankshaft Remove the ramp plate 7 8 7 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY GER EN Remove weight rollers Weight Roller MOVABLE DRIVE FACE INSPECTION Check each weight roller for wear or damage Measure each roller O D Service Limit 12 4mm replace if below SF10DA 12 4mm replace if below Movable Drive Face DRIVE PULLEY INSTALLATION Install the drive pulley collar and movable drive face onto the crankshaft Drive Pulley Collar 7 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY SUPERG SU Install the drive belt on the crankshaft Drive Pulley Face Install the drive face starting ratchet and washer then tighten the 17mm drive face nut Torque 34 3 39 2N m Keep grease or oil off the drive belt and drive pulley faces STARTER PINION REMOVAL Remove the left crankcase cover 7 2 Remove the drive pulley 7 6 Remove the starter pinion Starter Pinion INSPECTION Shaft Forcing Parts Inspect the starter pinion seat for wear Inspect the starter pinion for smooth operation Inspect the starter pinion shaft forcing parts fo
50. SHOOTING FUEL UNM oi pet e oi era cest ol od METER X SAW TICHES S sagar yu usa tt STOP SWITCH INSPECTION HORN BULB REPLACEMENT Gana INSTRUMENT HEADLIGHT 16 0 16 INSTRUMENT SWITCHES LIGHTS SERVICE INFORMATION GENERAL INSTRUCTIONS SUPER9 50 Wires should be connected other wires of the same color Couplers must be connected to other couplers of the same color e All plastic plugs have locking tabs that must be released before disconnecting and must be aligned when reconnecting e After installation of each switch a continuity check must be performed TROUBLESHOOTING Lights do not come on when ignition switch is ON e Burned bulb e Faulty switch e Broken or shorted wire e Fuse burned out Weak battery Poorly connected wire e Faulty winker Light dims e Faulty ignition coil e Wire or switch resistance too high e Faulty regulator rectifier Headlight does not change when dimmer switch is turn to Hi or Lo e Faulty or burned bulb e Faulty dimmer switch 16 1 Motor oil indicator light does not come on when motor oil is insufficient e Fuse burned out e Dead battery e Faulty ignition switch e Faulty instrument
51. SSION KYMCO CONTROL SYSTEM SUPER9 50 EXHAUST EMISSION RELATED SYSTEM INSPECTION Clean or replace the air cleaner Clean and adjust the carburetor Inspect the auto bystarter system Clean and inspect the spark plug Inspect the ignition system EXHAUST EMISSION TEST AND ADJUSTMENT Start the engine and warm up for several minutes Engine surface temperature 50 60 C 2 Adjust the idle speed to SHIOAD 2000 100rpm SF10DA 1900x100rpm 3 Connect the emission tester sampling pipe to the exhaust muffler Standard CO 340 5 HC 7000PPM max 4 If CO or HC exceeds the specified values adjust the carburetor air screw A S until CO and HC are within the specified standard values A S Opening SH10AD Tat turns SF10DA 1 turns 5 If the adjustment of carburetor makes no difference inspect exhaust emission related system 17 3
52. Water Pump Shaft pump assembly 11 10 KYMCO 11 COOLING SYSTEM SUPER9 50 Install the dowel pins and then install the Water Pump Assembly water pump assembly to the right crankcase Tighten the three bolts to secure the water pump assembly Install the two timing cap bolts and the timing cap When installing the water pump assembly aligning the tab on the water pump shaft with the groove on the A C generator nut WATER PUMP IMPELLER Mechanical Seal Seal Washer Porcelain INSTALLATION When the mechanical seal is replaced a new seal washer must be installed to the impeller Install the impeller onto the water pump shaft Torque 9 8 13 723 The impeller has left hand threads Dowel Pins Impeller Install the two dowel pins and new gasket Sy Install the water pump cover tighten the three bolts Torque 7 84 11 76N m 11 11 11 COOLING SYSTEM THERMOSENSOR THERMOSENSOR REMOVAL Remove the seat met in box and frame body cover Drain the coolant Disconnect the thermosensor wire Remove the thermosensor THERMOSENSOR INSPECTION Suspend the thermosensor in a pan of water over a burner and measure the resistance through the sensor as the water heats up 50 80 100 120 THERMOSENSOR INSTALLATION Apply 3 BOND 1212 sealant or equivalent to the cylinder head threads and install it into the thermost
53. a timing light Engine speed does not increase sufficiently Clogged air cleaner O Clogged fuel filter I 1 O Clogged exhaust muffler Faulty auto bystarter Faulty charcoal canister Correct timing Incorrect timing O Faulty CDI unit Faulty A C generator Test cylinder compression using a compression gauge EE 0 Worn cylinder and piston rings QO Blown cylinder head gasket Check carburetor for clogging Faulty reed valve Clogged carburetor jets Remove spark plug and inspect Normal Abnormal compression compression gt Not Clogged Clogged gt Plug not fouled or Plug fouled or discolored discolored Fouled spark plug Q Incorrect heat range plug Check if engine overheats Mixture too lean Engine does not overheats Rapidly accelerate or run at high speed 1 27 Engine overheats Poor quality fuel I 1 O Excessive carbon build up in combustion chamber Ignition timing too early r Excessive carbon build up in Engine does not knock Engine knocks combustion chamber I 1 Q Poor quality fuel r 9 Clutch slipping
54. al Torque Rear axle nut 78 4 98 0N m Brake Caliper Bolts Axle Nut INSTALLATION Install the rear wheel and apply SAE30 engine oil to the axle threads Then tighten the rear axle nut Torque values Rear axle nut 107 8 127 4N m Rear Axle Nut 14 REAR BRAKE REAR FORK REAR dC KYMCO WHEEL REAR SHOCK ABSORBER 9 50 REAR BRAKE DRUM 4 Remove the rear wheel gt 14 3 Inspect the rear brake drum Measure the rear brake drum I D Service Limit 95 5mm replace if over BRAKE LINING INSPECTION Measure the brake lining thickness Service Limit 2 0mm replace if below Keep oil or grease off the brake linings REAR BRAKE DISASSEMBLY Brake Arm Brake Shoes Remove the rear brake adjusting nut and disconnect the rear brake cable Remove the rear brake shoes Adjusting Nut 14 5 14 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER SUPER9 50 Remove the brake arm bolt to remove the brake arm wear indicator plate and felt seal Brake Arm Bolt Remove the brake cam Wear Indicator Plate Brake Arm REAR BRAKE ASSEMBLY Apply grease to the anchor pin and brake shoe moving parts Apply grease to the brake cam and install it Apply engine oil to the felt seal and install it Wear Indicator Plate to the brake cam Install the wear indicator plate Align the wide tooth of the wear indicator plate with the wide groove on the brake cam
55. arness Rear Brake Control Cable 1 19 KYMCO 1 GENERAL INFORMATION SUPER9 50 Fuel Filler Fuel Tank Breather Tube Oil Meter Fuel Filter Fuel Tube Fuel Pump Ignition Coil Fuel Pump Vacuum Tube Oil Filter Thermostat 1 20 KYMCO 1 GENERAL INFORMATION SUPER9 50 Ignition Coil Wire Harness Throttle Cable Water Hose Oil Tube SE Plug Auto Bystarter ap Wire Oil Meter Fuel Pump Fuel Tube Ignition Coil Fuel Unit Wire Air Injection Air Cleaner 1 21 1 GENERAL INFORMATION SUPER9 50 WIRING DIAGRAM SF10DA PI E EY 5 See Ers 1 48255 JE A RR mm de 58 1 22 KYMCO SUPER 9 50 1 GENERAL INFORMATION SH10DA a ul 1 23 KYMCO Engine does not Engine fires but does not start Remove spark plug and inspect again fire gt Dry spark plug Wet spark plug 1 GENERAL INFORMATION SUPER9 50 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment Symptom Probable Cause Check if fuel r
56. at housing Connect the thermosensor wire Fill the reserve tank with coolant 43 10 Install the frame body cover met in box and seat 2 3 sure air from cooling system KYMCO SUPER9 50 Thermosensor Thermosensor h KYMCO 11 COOLING SYSTEM 9 50 Thermostat Housing Screws THERMOSTAT THERMOSTAT REMOVAL Remove the seat met in box and frame body cover Drain the coolant Disconnect the water hose from the thermostat housing Water Hose Thermostat Remove the two screws and separate the thermostat housing cover Remove the thermostat from the thermostat housing THERMOSTAT INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to check its operation Technical Data mm Valve lift 3 5 4 5mm Do not let the thermostat touch the Thermostat quo as it will give a false reading e Replace the thermostat if the valve stays open at room temperature eTest the thermostat after it is opened for about 5 minutes and holds the temperature at 70 11 1 KYMCO 11 COOLING SYSTEM SUPER9 50 THERMOSTAT INSTALLATION The installation sequence is the reverse of removal Fill the cooling system with the specified coolant 3 10 11 14 KYMCO 12 SUPER9 50 CARBURET
57. bar covers 2 7 First drain the brake fluid from the hydraulic brake system Disconnect the front stop switch wire When servicing the brake system use shop towels cover rubber plastic Stop Switch Wire Connector parts and coated surfaces to avoid being contaminated by brake fluid e When removing the brake fluid tube Snap Ring Rubber Cover bolt be sure to plug the tube end to connector avoid brake fluid 1 Remove the brake fluid tube bolt Remove the two bolts attaching the brake master cylinder Remove the brake master cylinder DISASSEMBLY Remove the brake lever bolt and the brake Remove the piston rubber cover snap ring from the brake master cylinder ll Snap Ring Pliers Close Remove the washer main piston and spring Master Cylinder Spring Main Piston from the brake master cylinder Clean the inside of the master cylinder and brake reservoir with brake fluid Snap Ring Rubber Cover 13 8 13 STEERING HANDLEBARFRONT WHEELFRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 INSPECTION Measure the brake master cylinder Inspect the master cylinder for scratches or cracks Service Limit 12 75mm Measure the brake master cylinder piston O D Service Limit 12 645mm Before assembly inspect the Ist and 2nd rubber cups for wear ASSEMBLY BP Before assembly apply brake fluid to all removed parts In
58. be cause it will damage the brake system 13 10 13 STEERING HANDLEBARFRONTWHEELFRONT O KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 BRAKE FLUID BLEEDING Keep the handlebar upright and remove the brake reservoir cover and diaphragm Add the specified brake fluid to the upper limit Do not allow dust water to enter brake system during refilling e When servicing the brake system use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid In order to avoid spilling brake fluid connect a transparent hose to the bleed valve Bleed Valve Brake fluid spilled on brake pads or brake disk will reduce the braking effect Clean the brake pads and brake disk with a high quality brake degreaser Bleed Valve Fully apply the brake lever and then loosen the brake caliper bleed valve to drain the brake fluid until there 15 no air bubbles in the brake fluid Then tighten the bleed valve Repeat these steps until the brake system is free of air BRAKE CALIPER REMOVAL First drain the brake fluid from the hydraulic brake system Remove the brake fluid tube bolt Remove the two bolts attaching the brake caliper Fluid Tube Bolt Bolts Remove the brake caliper Brake Pad DISASSEMBLY Remove the two brake pads dowel pins from the brake caliper Remove the brake pads Dowel Pin 13 11 13 STEERING HANDLEBAR FRONT WHEELF
59. bearing e Worn or damaged cylinder and piston Compression too high overheating or knocking Abnormal noisy piston rings e Excessive carbon build up in cylinder head e Worn stuck or broken piston rings or on piston head e Worn or damaged cylinder 6 1 KYMCO 6 CYLINDER HEAD CYLINDER PISTON 9 50 CYLINDER HEAD Spark Plug Cap REMOVAL SHI0AD Remove the rear carrier Remove the frame body cover 22 2 Drain the coolant Disconnect the thermosensor wire from the thermosensor Disconnect the water hose from the thermostat housing Remove the spark plug cap Remove the two joint lock nuts on the front of the exhaust muffler and then remove the two exhaust muffler lock bolts The installation sequence is the reverse of removal When installing the exhaust muffler first tighten the two nuts on the front and then tighten the two bolts Remove the spark plug Remove the cylinder head bolts and the cylinder head gt Loosen the bolts diagonally in 2 or 3 times Remove the cylinder head gasket Spark Plug Cylinder Head 6 2 KYMCO 6 CYLINDER HEAD CYLINDER PISTON SUPER9 50 Spark Plug Cap CYLINDER HEAD REMOVAL SFI10DA Remove the rear carrier Remove frame body cover 42 2 Remove the spark plug cap Remove the three bolts attaching the fan cover to remove the fan cover Remove the two joint lock nuts on the front of the exhaust muffler and then remove the
60. box carrier frame body cover 522 2 Disconnect the A C generator connector Measure the resistances between the charging coil terminals white green and lighting coil terminals yellow green Resistances Charging coil white green 0 2 1 2 Lighting coil yellow green 0 3 1 00 Refer to 8 3 for A C generator removal 27 A C Generator Connector 15 5 15 ELECTRICAL EQUIPMENT SUPER9 50 RESISTOR INSPECTION Remove the front upper lower cover 42 3 Measure the resistance between the resistor B pink wire and ground Measure the resistance between the resistor A green black wire and ground Resistances Resistor A 9 9 10 50 Resistor B 5 6 6 2Q gt Faulty resistor is the cause of faulty operation of the auto bystarter REGULATOR RECTIFIER INSPECTION Resister Resister B Remove the front upper lower cover 522 3 Disconnect the regulator rectifier wire Bolt coupler and remove the bolt to remove the regulator rectifier Measure the resistances between the terminals Replace the regulator rectifier if the readings are not within the specifications in the table below e Due to the semiconductor in circuit it is necessary to use a specified tester for accurate testing Use of an improper tester in an improper range may give false readings e Use a Sanwa Electric Tester 07208 0020000 or Kowa Electric Tester CES TH 5H The pro
61. ct it to the oil pump Bleed air from the oil inlet line first then bleed air from the oil outlet line OIL OUTLET LINE BLEEDING 1 Disconnect the oil outlet line and bend it into U shape Force air out of the tube by filling it with oil 2 Start the engine and allow it to idle with the oil control lever in the fully open position Visually check the oil flow 3 If there is no oil flowing out within 1 minute bleed air from the oil inlet line and oil pump 7 Oil Outlet Line e Never run the engine in a closed area Do not increase the engine speed at will 4 4 KYMCO 4 LUBRICATION SYSTEM SUPER9 50 OIL TANK Oil Meter OIL TANK REMOVAL Remove the seat and met in box 2 2 Remove the battery Remove the battery cover screw and the battery cover Remove the oil meter connector Remove the two bolts attaching the oil tank Disconnect the oil inlet line Drain the oil inside the oil tank into a clean container Remove the oil tank The installation sequence is the reverse of removal Wire Connector Bolts Connect the oil line properly e Bleed air from the oil pump after installation e The oil tube clip at the oil tank side must be locked from inside of the oil tube joint 4 5 KYMCO 5 ENGINE REMOVAL INSTALLATION SUPER9 50 ENGINE REMOVAL INSTALLATION SER V ICE INFORMATION
62. ct the front and rear stop switch wire couplers Check for continuity between the wire terminals when the front rear brake lever is applied 16 6 16 INSTRUMENT SWITCHES LIGHTS SUPER9 50 Horn Terminal Battery HORN INSPECTION Remove the front upper lower cover 42 3 Disconnect the horn wire couplers The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals FRONT TURN SIGNAL LIGHT REPLACEMENT Remove the turn signal light shell and the bulb Replace with new ones ap Replace with new bulbs of same specifications Turn Signal Light Bulb Taillight Shell TAILLIGHT STOPLIGHT REAR TURN SIGNAL LIGHT BULB REPLACEMENT Taillight Shell Removal Remove two screws attaching the taillight shell Remove the taillight shell and stop light bulb Remove the rear turn signal light bulbs The installation sequence is the reverse of removal Screws 16 7 16 INSTRUMENT SWITCHES LIGHTS SUPER9 50 INSTRUMENT Instrument Bulbs Replacement Remove three screws attaching the instrument bulbs Remove the instrument bulbs cover Remove the bulbs and replace with new ones SPEEDOMETER REMOVAL Disconnect the speedometer cable Disconnect the speedometer wire connector Remove the two screws attaching the speedometer Remove the speedometer The installation sequence is the reverse of removal Wire Couplers HEADLIGHT Bulb S
63. d line e Unevenly worn brake caliper Front wheel wobbling e Bent rim e Loose front axle e Bent spoke plate e Faulty tire e Improperly tightened axle nut Soft front shock absorber e Weak shock springs Insufficient damper oil Front shock absorber noise e Slider bending e Loose fork fasteners e Lack of lubrication 13 2 13 STEERING HANDLEBARFRONT WHEELFRONT O KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 STEERING HANDLEBAR Brake Master Cylinders REMOVAL Remove the handlebar front and rear covers 52 7 Remove front brake master cylinder attaching bolts Remove the front upper cover 22 3 Remove the front lower cover 2 3 Remove the leg shield 42 4 Remove the floor board 2 5 Throttle Grip Remove the four screws attaching the right and left handlebar switches Disconnect the throttle cable from the throttle grip and remove the throttle grip from the handlebar Screws Throttle Cable Remove the handlebar lock nut and take out the bolt Remove the handlebar Lock Nut Bolt 13 3 13 STEERING HANDLEBAR FRONT WHEELFRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 INSTALLATION Install the handlebar onto the steering stem and install the handlebar lock nut and bolt Tighten the bolt to the specified torque Torque 39 2 49 0N m Lock Nut Bolt Lubricate the throttle grip front end with Throttle Cable Powe grease and
64. 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 Do not remove the transmission case cover except for necessary part replace ment When replacing the drive shaft also replace the bearing and oil seal Drive Shaft Bearing Countershaft Bearing Oil Seal 8 3 KYMCO 8 FINAL REDUCTION SUPER9 50 BEARING REPLACEMENT Drive Shaft Bearing Transmission Case Cover Remove the transmission case cover bearings using the bearing remover Remove the final shaft oil seal Bearing Remover Set Bearing Outer Driver Handle A Drive new bearings into the transmission case cover BEARING REPLACEMENT Left Crankcase Cover Remove the drive shaft Remove the drive shaft oil seal Remove the left crankcase bearings using the bearing remover Bearing Remover Set 8 4 KYMCO 8 FINAL REDUCTION SUPER9 50 Drive new bearings into the left crankcase i Install a new drive shaft oil seal A Aa FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Drive Shaft Install the countershaft gear into the left crankcase Countershaft Gear KYMCO 8 FINAL REDUCTION SUPER9 50 Dowel Pins Install the final gear and final shaft into the left crankcase Install the dowel pins and a new gasket Install the transmission case cover
65. e battery terminals to prevent sparks near the battery e Charge the battery according to the current specified on the battery surface Charging current Standard 0 4A Quick 4A Charging time Standard 5 hours Quick 0 5 hours After charging Open circuit voltage 12 8V min e Quick charging should only be done in an emergency e During quick charging the battery temperature should not exceed 45 e Measure the voltage 30 minutes after the battery is charged L Battery Black Front Tool Box Red KYM SUPER9 50 Charging Lamp Red 15 4 C KYM 15 ELECTRICAL EQUIPMENT SUPER9 50 PERFORMANCE TEST Warm up the engine Remove the floor mat and battery cover gt Use a fully charged battery to check the charging system output Stop the engine and open the fuse box Disconnect the wire lead from the fuse terminal Connect an ammeter between the wire lead and fuse terminal as shown Connect the battery positive terminal to the voltmeter positive probe and battery negative terminal to the voltmeter negative probe Start the engine gradually increase engine speed to test the output Charging Limit Voltage 14 5 0 5V 8000rpm If the limit voltage is not within the specified range check the regulator rectifier A C GENERATOR CHARGING COIL INSPECTION Inspect with the engine installed Remove met in
66. e fuel tube and auto bystarter wire connector Route the auto bystarter wire correctly and properly Install the carburetor gt 12 4 Insulator Install the air cleaner onto the carburetor and tighten the band screw Install the met in box 42 3 AIR SCREW ADJUSTMENT Remove met in box 2 3 Warm up engine before air screw adjustment Turn the air screw clockwise until it seats lightly and back it to the specification given Air Screw Opening SHIODA 1 3 2 turns Start the engine and turn the air screw in or Fuel Tube out slowly to obtain the highest engine speed not force the air screw against its seat to prevent damage Turn the throttle stop screw to obtain the specified idle speed Idle Speed SH10DA 2000 100rpm Slightly increase the engine speed and make sure that the engine does not miss or run erratic If the adjustment of the air screw within the range of turn makes no difference to the engine performance check other related items Throttle Stop Screw 12 10 KYMCO 12 CARBURETOR SUPER9 50 REED VALVE Bolts REMOVAL Remove the rear carrier Remove the frame body cover Remove the four intake manifold bolts and gasket Remove the reed valve and gasket Intake Manifold INSPECTION Reeds Reed Stopper Check the reed valve for damaged or weak reeds Check the reed valve seat for cracks damage or clearance betwe
67. e speedometer gear unit Separate inner fenders The installation sequence is the reverse of removal EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts Remove the two exhaust muffler lock bolts to remove the exhaust muffler Remove the exhaust muffler joint packing collar The installation sequence is the reverse of removal Torque Exhaust muffler joint lock nut 11 8N m Exhaust muffler lock bolt 34 3N m Screws Fender Inner Fender Nut Screws Joint Lock Nut 2 6 Lock Bolts KYMCO 2 EXHAUST MUFFLER FRAME COVERS SUPER9 50 HANDLEBAR COVER REMOVAL Screws Remove the four screws attaching the handlebar lower cover Remove the handlebar lower cover Remove the four screws attaching the handlebar upper cover Remove the handlebar upper cover The installation sequence is the reverse of removal Screws 2 7 KYMCO 3 INSPECTION ADJUSTMENT SUPER9 50 INSPECTION ADJUSTMENT SERVICEINEORMATION22 rele 32 INSPECTION AND MAINTENANCE SCHEDULE 3 2 PUBLADINE PUBL Hip TER 5 3 3 5 THROTTLE OPERATION ege 3 5 AIR EE E 256 SPARK PLUG Led 2 7 IGNEFION u u u 227 CYLINDER COMPRESSION 3 8 FINAL REDUCTION GEAR e 3 9 DRIVE E
68. eaches carburetor by loosening gt drain screw Empty fuel tank Fuel reaches Fuel does not Clogged float valve carburetor reach carburetor Clogged charcoal canister O Clogged fuel filter Faulty auto fuel valve Remove spark plug and install it into spark plug cap to test spark by gt connecting it to engine Faulty spark plug ground Fouled spark plug Faulty CDI unit Spark jumps Weak or no spark _ Faulty A C generator Broken or shorted ignition coil Broken or shorted exciter coil Test cylinder Faulty ignition switch compression g O Burned or worn cylinder piston Normal Low or no Q Faulty reed valve compression compression 9 Blown cylinder head gasket Leaking crankcase Start engine by follow Faulty crankcase oil seal ing normal starting gt procedure r Incorrectly adjusted idle Air leaking through intake pipe Incorrect ignition timing Flooded carburetor Wait for 30 minutes and then remove the carbu retor auto choke circuit hose and blow the hose with mouth Not clogged Clogged L Q Throttle valve excessively open _ Faulty auto bystarter 1 24 1 GENERAL INFORMATION KYMCO SUPER9 50 ENGINE STOPS IMMEDIATELY AFTER IT STARTS Inspection Adjustment Check if fuel reaches carburetor by loose
69. ecified idle speed the ignition timing is correct if the mark on the flywheel aligns with the index mark on the crankcase cover Also use a timing light to check the advance Raise the engine speed to 4 000rpm The index mark should be between the advance marks CYLINDER COMPRESSION Warm up the engine before compression test Remove the center cover and spark plug cap Remove the spark plug Insert a compression gauge Open the throttle valve fully and push the starter button to test the compression Compression 11 8 2kg cm If the compression is low check for the following Leaky valves Valve clearance to small Leaking cylinder head gasket Worn pistons Compression Gauge Worn piston cylinder If the compression is high it indicates that carbon deposits have accumulated on the combustion chamber and the piston head 3 8 KYMCO 3 INSPECTION ADJUSTMENT SUPER9 50 FINAL REDUCTION GEAR OIL Place motorcycle its main stand on level ground Stop the engine and remove the check bolt The oil level shall be at the oil check bolt hole If the oil level is low add the recommended oil SAE90 to the proper level Install the oil check bolt Make sure that the sealing washer is good condition OIL CHANGE Remove the oil check bolt Remove the oil drain bolt and drain the oil thoroughly Install the oil drain bolt Torque 9 8N m
70. eflector amp License Plate damage Counter Operation Exhaust Point looseness and damage See Muffler Exhaust muffler performance d Body amp Frame and damage 5 Abnormal Conditions Check if the abnormal Happened Last conditions occur again Time Lubrication points Remove carbon deposits on Others combustion chamber breather hole and exhaust muffler 3 4 KYMCO 3 INSPECTION ADJUSTMENT SUPER9 50 FUEL LINE FUEL FILTER Remove the center cover Check the fuel lines and replace any parts which show signs of deterioration damage or leakage Check for dirty or clogged fuel filter and replace with a new one if it is clogged not smoke or allow flames or sparks in your working area Fuel Filter Fuel Line THROTTLE OPERATION Check the throttle grip for smooth movement Measure the throttle grip free play Free Play 2 6mm Major adjustment of the throttle grip free play Lock Nut is made with the adjusting nut at the A carburetor side Adjust by loosening the lock nut and turning the adjusting nut Adjusting Nut KYMCO 3 INSPECTION ADJUSTMENT SUPER9 50 Minor adjustment is made with the adjusting nut at the throttle grip side Slide the rubber cover out and adjust by loosening the lock nut and turning the adjusting nut Adjusting Nut Lock Nut AIR CLEANER Screws Remove the seven a
71. el balls Excessive wheel bearing play Steering handlebar pulls to one side Bent Loose axle nut mO Misaligned front and rear wheels 2 Bent front fork 1 30 1 GENERAL INFORMATION POOR SUSPENSION PERFORMANCE Symptom Suspension is too soft KYMCO SUPER9 50 Probable Cause Front and rear tire pressures are normal Weak shock spring Excessive load Suspension is too hard Shock damper oil leaking r Bent fork tube or shock rod Suspension is noisy Q Fork slider and tube binding O Fork tube and spring binding A POOR BRAKE PERFORMANCE Symptom Index mark on brake panel aligns with wear Indicator arrow Q Fork slider and tube binding Probable Cause Adjust brake according to standards 0 Worn brake linings Worn brake cam contacting area on Brake squeaks brake shoes Worn brake cam Worn brake drum r Worn brake linings Brake performance is Expanding poor Brake Hydraulic Brake Foreign matter on brake linings _ Rough brake drum contacting area Sluggish or elongated brake cables 9 Brake shoes improperly contact brake drum 9 Water and mud in brake syste
72. en the seat and reed Replace the valve if necessary Do not disassemble or bend the reed stopper To do so can cause loss of engine power and engine damage any of the stopper reed or valve seat is faulty replace them as a unit Reed Valve Seat INSTALLATION Install the reed valve in the reverse order of removal e Install a new gasket with the gasket indentation aligned with the reed valve e After installation check for intake air leaks 12 11 13 STEERING HANDLEBARFRONT WHEELIFRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK SERVICE INFORMATION 13 1 TROUBLESHOOTING 13 2 STEERING HANDLEBAR 13 3 FRONT WHEEL 13 5 FRONT BRAKE 13 8 BRAKE CALIPER 13 11 FRONT SHOCK ABSORBER 13 14 FRONT FORK 13 18 13 0 13 STEERING HANDLEBARFRONT WHEELIFRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 SERVICE INFORMATION GENERAL INSTRUCTIONS Remo
73. fication Wear Indicator Mark Brake Disk INSTALLATION Copper Washers Install the brake caliper to the rear fork and tighten the two bolts Torque 24 5 34 3N m Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt Fill the brake reservoir with the specified brake fluid and bleed air from the brake system gt 13 11 When installing the brake fluid tube be sure to install the two copper sealing washers Fluid Tube Bolt Bolts 14 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER SUPER 9 50 REAR FORK SF10DA REMOVAL Remove the exhaust muffler 52 6 Remove the rear brake caliper gt 14 2 Remove the rear axle nut and remove the collar Remove the rear fork The installation sequence is the reverse of removal Torque Rear fork bolt 19 6 29 4N m Rear axle nut 78 4 98 0N m Collar Rear Fork Bolts REMOVAL Remove the exhaust muffler 2 6 Remove the rear brake caliper gt 14 2 Remove the rear fork Remove the rear axle collar Remove the rear wheel REMOVAL Remove the exhaust muffler 2 6 Remove the rear axle nut to remove the rear wheel Rear Axle Nut 14 3 14 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER SUPER9 50 INSPECTION Measure the rear wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over INSTALLATION The installation sequence is the reverse of remov
74. hat the ignition coil is cold and hot A C GENERATOR Exciter Coil Pulser Coil Inspection This test is performed with the stator installed in the engine Remove the met in box 12 4 Disconnect the A C generator wire connector Measure the pulser coil resistance between the blue yellow wire and ground Resistance 20 80 1600 15 9 KYM SUPER9 50 Ignition Coil Tester 07508 0070100 Watch Window ci we 1 Blue Yellow 15 ELECTRICAL EQUIPMENT SUPER9 50 CDI UNIT INSPECTION Coupler Open the front tool box and remove bolt Remove the front tool box 2 4 Disconnect the CDI coupler and remove the CDI unit CDI Unit CDI CIRCUIT INSPECTION Measure the resistance between the terminals Replace the CDI unit if the readings are not Black Yellow Green within the specifications in the table below e Due to the semiconductor in circuit it is necessary to use a specified tester for accurate testing Use of an improper tester in an improper range may give false readings e Use a Sanwa Electric Tester or Kowa Electric Tester TH 5H e In this table Needle swings then returns indicates that there is a charging current applied to a condenser The needle will then remain at co unless the condenser is discharged Blue Yellow Black Blue Use the X range for the Sanwa Tester Use the 1000 range for the Kowa Tester
75. he brake disk runout is within the specified service limit Check if the brake pad wear exceeds the wear indicator line e Keep grease or oil off the brake disk to avoid brake failure Wear Indicator Line Brake Disk BRAKE DRUM SHOE Brake Shoe Wear Replace the brake shoes if the arrow on the brake arm aligns with reference mark A the brake panel when the brake is fully applied Adjusting Nuts Fs VENT D e 2 3 Ee Brake Drum Wear Damage Check the brake drum appearance for damage Check if the brake lining wear is within the specified service limit Check the brake operation for abnormal noise and brake drum inside for wear or damage A Marks Rear 3 12 KYMCO 3 INSPECTION ADJUSTMENT SUPER9 50 NUTS BOLTS FASTENERS Check all important chassis nuts and bolts for looseness Tighten them to their specified torque values if any looseness is found WHEELS TIRES Check the tires for cuts imbedded nails or other damages Check the tire pressure Tire pressure should checked when tires are cold Tire Pressure Pressure Gauge ree Tome 1 75kg cm 1 75kg cm 2 00kg cm 2 2 25kg cm STEERING HANDLEBAR Raise the front wheel off the ground and check that the steering handlebar rotates freely If the handlebar moves unevenly binds or has vertical movement adjust the steering head bearing SUSPENSION Check the action of the
76. he front shock absorber tube in a vise Remove the lock nut on the front shock absorber tube Take out the shock absorber spring and damper rod When holding shock absorber tube place a shop towel to protect it and do apply too much force Lock Nut Shock Absorber Tube INSPECTION Shock Absorber Tube Inspect the following items and replace if necessary eFront shock absorber tube bending damage or wear eWeak front shock absorber spring eDamper and damper rod bending eOil seal damage or wear 13 15 13 STEERING HANDLEBARFRONT WHEELFRONT O KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 Measure the front shock absorber spring free length Service Limit 233mm replace if below ASSEMBLY Install the damper spring onto the damper rod and then install them into the front shock absorber tube Install the shock absorber spring onto the front shock absorber tube Set the front shock absorber tube in a vise and then tighten the lock nut When holding the shock absorber tube y place a shop towel to protect it and do apply too much force Set the front shock absorber in a vise Insert the shock absorber tube into the shock absorber and then install the copper washer and tighten the damper rod hex bolt Apply locking agent to the washer and hex bolt and install them together Add engine oil into the front shock absorber Torque 14 7 29 4N m Specified O
77. he oil line with motor oil before connecting it SPECIFICATIONS e Recommended Motor Oil SAE20W20 2 stroke Motor Oil e Oil Capacity 1 7 liter Light comes on 0 3 liter TROUBLESHOOTING Excessive white smoke or carbon deposits on spark plug e Oil pump not properly synchronized excessive oil Poor quality oil Engine overheating Oil pump not properly adjusted insufficient oiling Poor quality oil Seized piston No oil in tank or clogged oil line e Oil pump not properly adjusted insufficient oiling e Air in oil line e Faulty oil pump Oil not flowing out of tank to engine e Clogged oil tank cap breather hole e Clogged oil filter 4 1 KYMCO 4 LUBRICATION SYSTEM SUPER9 50 OIL PUMP REMOVAL Control Cable Oil Pump Do not allow foreign matters to enter the crankcase Before removing the pump clean the oil pump and crankcase surfaces Remove the met in box 2 2 Disconnect the oil pump control cable from Bolt the pump body Disconnect the oil inlet line from the oil pump Then disconnect the oil outlet line Before disconnecting the oil line clip the oil line to avoid oil flowing out and then plug the oil line after it is disconnected Remove the oil pump control cable plate bolt and copper washer Remove the oil pump from the crankcase Control Cable Plate O ring OIL PUMP INSPECTION Remove the oil pump and inspect the following items e Weakened
78. he retainer clockwise to secure it Groove OIL METER B Float Oil Meter INSPECTION Remove the met in box 52 2 Remove frame body cover 42 2 Disconnect the oil meter wire connectors and remove the oil meter Keep the oil meter float at the lower position Measure the resistances between the wire terminals as and shown in the left figure Green Red Black 5 160 k Green Black Before removing ol meter be sure to drain the motor oil and do not allow sparks or flames near the working area Oil Meter Operation Inspection Connect the oil meter wire connectors and turn the ignition switch ON Measure the resistance between the wire terminals with the float at upper position Green Red Black About 3400 i Before performing following test operate the turn signals to determine that the battery circuit is normal 16 3 Li ght OFF 4 5 1 0mm Light A K YM 16 INSTRUMENT SWITCHES LIGHTS SUPER9 50 Move the oil meter float up and down to see if the oil indicator light will go out and come on Oil Indicator Light If the oil indicator light does not light check for burned bulb loose wire or connector After correction check again according to the method mentioned above SWITCHES IGNITION SWITCH INSPECTION Remove the front upper lower cover 42 3 Disconnect the ignition switch wire couplers a
79. il SS 8 Oil Capacity 52cc Hex Bolt 13 STEERING HANDLEBARFRONT WHEEL FRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 Install the oil seal Circlip Dust Boot Install the circlip Install the dusts seal and dust boot Dust Seal INSTALLATION Install the front shock absorbers onto the front fork Install and tighten the front shock absorber upper mount bolts Tighten the lower mount bolts 2 Align the upper mount bolt hole with the groove on the front fork Install the front wheel gt 13 7 Q di 13 17 13 STEERING HANDLEBAR FRONT WHEELFRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 FRONT FORK REMOVAL Remove the handlebar covers 2 6 Remove the steering handlebar gt 13 4 Remove front upper cover 42 5 Remove the front lower cover 2 5 Remove the front inner fender 2 6 Remove front wheel gt 13 5 Remove the front brake caliper gt 13 11 Hold the steering stem top cone race and remove the steering stem lock nut Lock Nut Remove the top cone race and remove the front fork gt Be careful not to lose the steel balls 26 on top race and 29 on bottom race Inspect the ball races cone races and steel balls for wear or damage Replace if necessary Top Cone Race BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race using a chisel Drive a new bottom cone race into place with a proper driver
80. ir cleaner case cover screws and the cover Air Cleaner Case Cover Remove the air cleaner element Air Cleaner Element Check the element and replace it if it is Am excessively dirty or damaged e CHANGE INTERVAL CTT UY More frequent replacement is required when riding in unusually dusty or rainy areas The air cleaner element has a viscous type paper element Do not clean it with compressed air sure to install the air cleaner element and cover securely 3 6 KYMCO 3 INSPECTION ADJUSTMENT SUPER9 50 SPARK PLUG Remove the frame center cover Remove the spark plug cap and spark plug Check the spark plug for wear and fouling deposits Clean any fouling deposits with a spark plug cleaner or a wire brush Spark Plug Specified Spark Plug BR8HSA Measure the spark plug gap 0 6 0 7mm Spark Plug Gap 0 6 0 7mm 3 Deformation gt lt When installing first screw in the Gap spark plug by hand and then tighten it Cracks with a spark plug wrench Deposits Damage Torque 7 8 9 8N m Timing Cap IGNITION TIMING e Be gt e The CDI unit is not adjustable If the ignition timing is incorrect check the ignition system Remove the two timing cap bolts and the timing cap KYMCO 3 INSPECTION ADJUSTMENT SUPER9 50 Check the ignition timing with a timing light Mark When the engine is running at the sp
81. iversal bearing puller When separating the crankcase the oil seals must be removed Replace the oil seals with new ones Universal Bearing Puller CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 6mm replace if over Measure the connecting rod big end radial clearance at two points in the X and Y directions Service Limit 0 04mm replace if over 10 3 KYMCO 10 CRANKCASE CRANKSHAFT SUPER9 50 Measure the crankshaft runout Service Limit WEE MER 0 150mm 0 100mm replace if over replace if over Check the crankshaft bearings for excessive Play play The bearings must be replaced if they are noisy or have excessive play Play Axial Radial CRANKSHAFT INSTALLATION Wash the crankshaft in cleaning solvent and then check for cracks or other faults After check apply clean engine oil to all moving and sliding parts e Remove all gasket material from the crankcase mating surfaces Dress any roughness or irregularities with an oil stone 10 4 KYMCO 10 CRANKCASE CRANKSHAFT SUPER9 50 Drive a new crankshaft bearing into the right crankcase Drive a new crankshaft bearing into the left crankcase Install the crankshaft into the left crankcase Apply KYMCO ULTRA motor oil or molybdenum disulfide to the crank shaft bearings and connecting rod big end e Apply grease to the lip
82. lace if over Set each piston ring squarely into the cylinder using the piston and measure the end gap CONNECTING ROD SMALL END INSPECTION Install the piston pin and bearing in the connecting rod small end and check for excessive play Measure the connecting road small end Service Limit SHIODA 17 03mm replace if over SF10DA 17 03mm replace if over PISTON CYLINDER INSTALLATION First install the expander in the second ring groove Then install the top and second rings in their respective ring grooves The piston rings should be pressed into the grooves with even force After installation check and make sure that each ring is flush with the piston at several points around the ring A ring that will not compress means that the ring groove has carbon deposits in it and should be cleaned Expander 6 9 KYMCO 9 50 Piston Ring Second Ring KYMCO 6 CYLINDER HEAD CYLINDER PISTON 9 50 Install a new cylinder gasket on the mating surface between the cylinder and crankcase Cylinder Gasket Make sure that the ring end gaps are aligned with the piston ring pins in the ring grooves Lubricate the cylinder inside and piston rings with engine oil and install the piston into the cylinder while compressing the piston rings Be careful not to damage the piston Install the cylinder head Torque 14 7 16 66N m Install the exhaust muffler and tighten
83. lts Torque 24 5 34 3N m When installing the brake caliper be sure to position the brake disk between the two brake pads Fluid Tube Bolt Brake Caliper 13 13 13 STEERING HANDLEBARFRONT WHEEL FRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 Connect the brake fluid tube to the brake Brake Fluid Tube caliper and tighten the fluid tube bolt P d Torque 24 5 34 3N m the brake reservoir with the specified brake fluid and bleed air from the brake system 13 11 When installing the brake fluid tube be sure to install the two sealing washers FRONT SHOCK ABSORBER Front Fork REMOVAL Remove the front upper cover 22 3 Remove the front lower cover 2 3 Remove the front wheel gt 13 5 Remove front brake caliper 13 11 Remove the front shock absorber upper mount bolts Loosen the lower mount bolts to remove the front shock absorbers Shock Absorber Mount Bolts DISASSEMBLY Dust Boot Dust Seal Remove the dust boot Remove the dust seal Remove the circlip Circlip 13 14 13 STEERING HANDLEBARFRONT WHEELFRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 Set the front shock absorber in a vise Remove the damper rod hex bolt and copper washer Pull out the front shock absorber tube After the hex bolt is removed place container under the front shock absorber to drain the engine oil from it Hex Bolt Set t
84. m 4 Oil or grease on brake linings Faulty brake master cylinder Q Faulty brake caliper 1 31 Oil or grease on brake disk Deformed brake disk 6 Leaking brake fluid tube KYMCO 1 GENERAL INFORMATION SUPER9 50 OIL METER 1 Motor oil indicator light does not come on when there is no motor oil Ignition switch ON Inspection Adjustment Symptom Probable Cause Check battery circuit by gt operating turn signals Burned out fuse 2 Q Weak or dead battery Signals operate Signals dim remain Faulty ignition switch properly on or don t operate Loose or disconnected Connect indicator light bulb to battery for bulb P mos inspection Bulb lights Bulb does not light Burned out bulb Check connectors for 2 Loose wire connector Good Faulty 1 Broken wire harness Remove oil meter and Incorrectly connected wire check operation of indicator light by moving float Faulty float Good Pauly L Broken or shorted wire Float up Light off meter Float down Light on A 2 Motor oil is sufficient but the indicator light remains on Ignition switch ON Inspectio
85. mage Measure the clutch lining thickness Service Limit 2 0mm replace if below Measure the driven face spring free length Service Limit SHIODA 82 6mm replace if below SF10DA 82 6mm replace if below Check the driven face assembly for wear or damage Measure the driven face O D Service Limit 33 94mm replace if below Check the movable driven face for wear or damage Measure the movable driven face Service Limit 34 06mm replace if over Check the guide roller pins for stepped wear 7 13 7 KICK STARTER DRIVE PULLEY KYMCO CLUTCH DRIVEN PULLEY SUPER S 5n DRIVEN PULLEY FACE BEARING Inner Bearing REPLACEMENT Check the needle bearings in the driven face and replace them if they have excessive play damage or abnormal noise Drive the inner bearing out of the driven pulley face Remove the drive outer bearing out of the driven face Outer Bearing Bearing Outer Driver Drive a new outer bearing into the driven face with the sealed end facing up Seat the snap ring in its groove Pack all bearing cavities with 5 0 5 6g grease Specified grease 230 C Heat resistant grease 7 14 7 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY SUPER9 50 Drive in a new needle bearing into the Bearing Driver Pilot driven face with the mark facing up Outer Driver CLUTCH DRIVEN PULLEY ASSEMBLY Driven Pulley Seal First install the movable driven face onto
86. mover set 12mm Bearing remover set 15mm Crankcase assembly collar Crankcase assembly shaft Bearing outer driver 37x40mm Bearing outer driver 32x35mm Bearing driver pilot 17mm Bearing driver pilot 15mm Bearing driver pilot 12mm Bearing outer driver handle A TROUBLESHOOTING Engine starts but motorcycle won t move e Damaged transmission e Seized or burnt transmission Abnormal noise e Worn seized or chipped gears e Worn bearing Oil leaks e Oil level too high e Worn or damaged oil seal KYMCO 8 FINAL REDUCTION SUPER9 50 FINAL REDUCTION DISASSEMBLY Remove the rear wheel 14 2 Remove the left crankcase cover 57 2 Remove clutch driven pulley gt 7 11 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 NN Remove the final gear and countershaft Dowel Pin Driver shift Final Gear Countershaft Dowel Pin FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage Countershaft 8 2 KYMCO 8 FINAL REDUCTION SUPER9 50 Inspect the final gear and final shaft for wear damage or seizure Drive Shaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage Final Shaft Bearing Countershaft Bearing Final Shaft Inspect the
87. n Adjustment Symptom Probable Cause Check connectors for proper connection Loose or disconnected Good Fault connector Se Se Broken wire harness Remove oil meter and Incorrectly connected wire check operation of indicator light by gt moving float Fault Faulty float xs ee de Good 2 Broken or shorted wire in meter Damaged oil tank Foreign matters in oil tank 1 32 1 GENERAL INFORMATION FUEL GAUGE 1 Pointer does not register correctly Ignition switch ON Inspection Adjustment Check battery circuit by operating turn signals Symptom KYMCO SUPER9 50 Probable Cause Burned out fuse Remove fuel unit and check operation of pointer by moving float up and down Signals operate properly Signals dim remain on or don t operate Q Weak or dead battery Faulty ignition switch Loose or disconnected connector Broken wire harness Check operation of pointer by opening and shorting fuel unit terminal on wire harness side Pointer does no move t Pointer moves 0O Faulty float Pointer does not move Pointer moves 0 Broken or shorted fuel
88. n Spring or damage Check the friction spring for wear or damage O Kick Starter Driven Gear 7 3 KYMCO 7 KICK STARTER DRIVE PULLEY SUPER9 50 CLUTCH DRIVEN PULLEY Inspect the kick starter spindle and driven Kick Starter Spindle Forcing Part gear forcing parts for wear or damage Kick Starter Driven Gear Forcing Part KICK STARTER INSTALLATION Install the kick starter spindle bushing and return spring onto the left crankcase cover If the hooks of the return spring not be installed properly use a screw driver to press them into their locations respectively Kick Starter Spindle Friction Spring Properly install the kick starter driven gear Friction Spring and friction spring as the figure shown Kick Starter Driven Gear 7 4 7 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY Ae First install the washer and then the circlip onto the kick starter spindle Install the kick lever LEFT CRANKCASE COVER INSTALLATION First install the dowel pins and then the seal rubber Install the left crankcase cover and tighten the nine bolts diagonally Connect the drive belt cooling air tube and install the circlip 7 5 Washer Circlip Dowel Pins 7 KICK STARTER DRIVE PULLEY C KYMCO CLUTCH DRIVEN PULLEY ER DRIVE BELT Remove the left crankcase cover INSPECTION Check the drive belt for cracks separation or abn
89. nd check for continuity between the wire terminals oo Oe oe Ignition Switch Coupler IGNITION SWITCH REPLACEMENT Remove the front upper lower cover 22 3 Disconnect the ignition switch wire couplers Remove the two mounting bolts and remove the ignition switch The installation sequence is the reverse of removal Bolts 16 4 16 INSTRUMENT SWITCHES LIGHTS SUPER9 50 HEADLIGHT SWITCH INSPECTION Remove the handlebar lower cover 2 7 Disconnect the headlight switch wire coupler and check for continuity between wire terminals Headlight Switch L W DIMMER SWITCH INSPECTION Check for between wire terminals Dimmer Switch L TURN SIGNAL SWITCH INSPECTION Check for continuity between the wire terminals Symbol R L WR Turn Signal Switch SB O Gr 16 5 16 INSTRUMENT SWITCHES LIGHTS SUPER9 50 STARTER SWITCH INSPECTION Check for continuity between wire terminals Push the starter button when measuring YellowRed Symbol FREE PUSH Starter Switch G Y R HORN SWITCH INSPECTION Check for continuity between wire terminals Push the horn button when measuring Light Green Symbol mt PUSH O d G Horn Switch Lg STOP SWITCH INSPECTION Remove handlebar lower cover 2 7 Disconne
90. ning drain screw Symptom Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Fuel reaches carburetor Fuel does not reach carburetor Probable Cause O Empty fuel tank Clogged float valve Remove spark plug and install it into spark plug to test spark connecting it to engine ground u Test cylinder compression using a compression gauge Plug not fouled or Plug fouled or discolored discolored Weak or inter Good spark Check carburetor for clogging mittent spark Check ignition timing Clogged charcoal canister Clogged fuel filter Faulty auto fuel valve mO Fouled spark plug Incorrect heat range plug Fouled spark plug Faulty CDI unit Faulty A C generator Faulty ignition coil O Broken or shorted high tension wire 9 Faulty ignition switch rO Worn cylinder and piston Check carburetor air screw adjustment rings Normal Abnormal Q Blown cylinder head gasket compression compression Flaws in cylinder head Faulty reed valve Seized piston gt Not Clogged Clogged 0O Clogged carbure
91. o the battery terminals B Terminal caps shall be installed securely 1 5 KYMCO SUPER9 50 KYMCO 1 GENERAL INFORMATION SUPER9 50 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 B When taking out the connector the lock on the connector shall be released before operation E Hold the connector body when connecting or disconnecting it O E Do not pull the connector wire BR N B Check if any connector terminal is bending protruding or loose 1 6 KYMCO 1 GENERAL INFORMATION SUPER9 50 B The connector shall be inserted completely E If the double connector has a lock CL gt 5 lock it at the correct position 5Dv a Napping B Check if there is any loose wire Before connecting a terminal check for damaged terminal cover or loose O negative terminal j E Check the double connector cover for proper coverage and installation B Insert the terminal completely Check the terminal cover for proper coverage E 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 1 7 KYMCO 1 GENERAL INFORMATION SUPER9 50
92. ockets REMOVAL BULB REPLACEMENT Remove the front upper lower cover 2 3 Remove the bulb sockets and bulbs e The model adopts krypton gas bulb When installing do not directly touch the bulb glass with fingers e Use bulbs of the same specifications for replacement The installation sequence is the reverse of removal Coupler 16 8 17 EVAPORATIVE EXHAUST EMISSION KYMCO CONTROL SYSTEM SUPERGE EVAPORATIVE EXHAUST EMISSION CONTROL SYSTEM EXHAUST EMISSION CONTROL SYSTEM 17 1 EXHAUST e EE 17 2 EXHAUST EMISSION RELATED SYSTEM 5 17 3 17 0 17 EVAPORATIVE EXHAUST EMISSION KYMCO CONTROL SYSTEM SUPERS e EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system adopted by this model is an oxidizing catalytic converter which is located in the middle of the exhaust muffler to reduce pollutants in the exhaust emission Exhaust Muffler Diagram Catalytic Converter FUNCTION Function Oxidizing Reduce the concentration of The precious metal in the oxidizing catalytic Catalytic HC and CO in the exhaust converter is used to oxidize HC and CO in Convertos emission the exhaust emission into CO2 and H20 to avoid air pollution TROUBLESHOOTING Engine runs erratic at idle speed and Lack of power and high CO amp HO high fuel consumption 1 Clogged exhaust muffler 1 Clogged exhaust muffler 2 Faulty oxidizing catalytic converter
93. olant in the reserve tank Reinstall the drain hoses the radiator with the specified coolant The coolant freezing point should be 5 lower than the temperature of the riding area Headlight Aim Adjusting Bolt Upper Line Lower Line Reserve Cap Reserve Tank KYMCO 3 INSPECTION ADJUSTMENT SUPER9 50 Coolant capacity 1165cc Radiator capacity 825cc Reserve tank capacity 340cc Start the engine and check if there is no bubbles in the coolant and the coolant level is stable Reinstall the radiator cap If there are bubbles in the coolant bleed air from the system Fill the reserve tank with the recommended coolant up to the upper line BRAKE SYSTEM BRAKE LEVER Measure the front and rear brake lever free plays Free Play 10 20mm If the free plays do not fall within the limits Marks lt Rear gt turn the right and left adjusting nuts for adjustment Adjusting Nuts 3 11 KYMCO 3 INSPECTION ADJUSTMENT SUPER9 50 BRAKE FLUID Front Brake Reservoir Rear Brake Reservoir Turn the steering handlebar upright and check if the front rear brake fluid level is at the upper limit If the brake fluid is insufficient fill to the upper limit Specified Brake Fluid DOT 4 brake fluid level will decrease if the brake pads are worn BRAKE DISK BRAKE PAD Check the brake disk surface for scratches unevenness or abnormal wear Check if t
94. omatic centrifugal type Cylinder arrangement Single cylinder Reduction Combustion chamber type bal Bore x stroke mm 39 x 41 4 Front Axle Compression pressure 11 8 kg cm rpm Tire pressure Max output ps rpm 3 6 6500 kg cm torque N m rpm 3 92 6000 Turning Port 1mm Close Automatic controlled system Disk brake timing Exhaust Open G Disk brake S suspension jC 2 B type Rear Unitswing cearance cold Exhaust _ 18 shock absorber Idle speed rpm 2000 100rpm Double swing 20 m p uononpow WASA IMAA 8 4 Separate E Plunger type Full flow filtration 1 2 QC KYMCO 1 GENERAL INFORMATION SUPER9 50 Q PB s Displacement 49 4cc Fuel Used 3 5 22 J2000mpm EE Spark plu NGK Spark plug gap 0 6 0 7mm urojs g ond J032Jnq Ie pomnog uonius 130 70 12 Starting motor amp Dry multi disc clutch Operation Automatic centrifugal type Cylinder arrangement Single cylinder flat Reduction Hao qmd Axle Compression pressure kg cm rpm 20 m p uononpow WASA Tire pressure kg cm2 Turning Port 1mm Close Brake system Exhaust pn _ umm foe 0 _ eee 1900f1
95. ormal or excessive wear Measure the drive belt width Service Limit SHIODA 17mm replace if below SF10DA 17mm replace if below gt Use specified genuine parts for replace ment REPLACEMENT Remove the nine left crankcase cover bolts and left crankcase cover 57 2 Hold the clutch outer with the universal holder and remove the 14mm clutch outer nut and clutch outer Universal Holder Hold the drive pulley with the holder and Ratchet Drive Face remove the 17mm drive face nut A Fy awe Remove the starting ratchet Remove the drive pulley face Drive Face Nut 7 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY SUPERO Remove the drive belt from the clutch Clutch Driven Pulley driven pulley Drive Belt DRIVE BELT INSTALLATION Turn the driven pulley clockwise and lift it up to expand the drive belt groove and then install a new drive belt Drive Face Nut Drive Pulley Face Set the drive belt on the drive pulley Install the drive pulley face starting ratchet 17mm washer then tighten the drive face nut Torque 34 3 39 2N m When installing the drive face nut make sure that the tooth spaces of the drive pulley face and starting ratchet align with the teeth of the crankshaft Starting Ratchet 17mm Washer 7 7 7 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY SUPEB S 80 DRIVE PULLEY Drive Pulley Face Starting
96. ower Dead battery e Loose battery cable connection e Disconnected battery cable e Loose charging system connection e Fuse burned out e Loose connection or short circuit in ignition system e Faulty ignition switch e Loose connection or short circuit in lighting system Low power Charging system failure e Weak battery e Loose broken or shorted wire or connector Loose battery connection e Faulty regulator rectifier e Charging system failure e Faulty A C generator e Faulty regulator rectifier 15 1 15 ELECTRICAL EQUIPMENT IGNITION SYSTEM No spark at plug e Faulty spark plug Poorly connected broken or shorted wire Between A C generator and CDI unit Between CDI unit and ignition coil Between CDI unit and ignition switch Between ignition coil and spark plug e Faulty ignition switch e Faulty ignition coil e Faulty CDI unit e Faulty A C generator STARTING SYSTEM Starter motor won t turn e Fuse burned out e Weak battery e Faulty ignition switch e Faulty starter switch e Faulty front or rear stop switch e Faulty starter relay Poorly connected broken or shorted wire e Faulty starter motor SUPER9 50 Engine starts but turns poorly e Ignition primary circuit Faulty ignition coil Poorly connected wire or connector e Ignition secondary circuit Faulty ignition coil Faulty spark plug Poorly insulated plug cap Improper ignition timing Battery voltage
97. per range for testing is listed below A Red C Yellow SP 10D TH SH 1000 gt L gt em e 7 p unm b Ee B White D Green 15 6 15 ELECTRICAL EQUIPMENT SUPER9 50 IGNITION SYSTEM Ignition Switch A C Generator 15 7 K KYM 15 ELECTRICAL EQUIPMENT SUPER9 50 IGNITION COIL INSPECTION Continuity Test This test is to inspect the continuity of ignition coil Remove the met in box 412 4 Measure the resistance between the ignition coil primary coil terminals Resistance 20 C 0 153 0 1870 Measure the secondary coil resistance between the spark plug cap and the primary coil terminal as Figure A shown Resistance 20 C with plug cap 6 99 10 21KQ Measure the secondary coil resistance between the ignition coil terminal and the primary coil terminal as Figure B shown Resistance 20 C without plug cap 3 24 Ignition Coil 15 ELECTRICAL EQUIPMENT Performance Test Remove the ignition coil Inspect the ignition coil with an ignition coil tester Follow the ignition coil tester manufac turer s instructions Turn the changeover switch to 12V and connect the ignition coil to the tester 2 Turn the power switch ON and check the spark from the watch window Good Normal and continuous spark Faulty Weak or intermittent spark The test is performed at both conditions t
98. r for wear or damage mechanical seal seal washer must be replace as a set WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover Remove the two timing cap bolts and the timing cap Remove the three bolts attaching the water pump assembly Remove the water pump assembly and dowel pins zy Water Pump Assembly Water Hose Remove the water pump shaft from the water pump assembly Water Pump Assembly Water Pump Shaft 11 8 KYMCO 11 COOLING SYSTEM SUPER9 50 WATER PUMP BEARING Water Pump Assembly MECHANICAL SEAL REMOVAL Remove the water pump shaft inside bearing Inside Bearing Water Pump Assembly Drive the mechanical seal out of the water pump assembly from the outer Mechanical Seal Water Seal Remove the water pump shaft outer Outer Bearing bearing 11 9 KYMCO 11 COOLING SYSTEM SUPER9 50 WATER PUMP BEARING ae MECHANICAL SEAL INSTALLATION Drive a new water pump shaft outer bearing into the water pump assembly from the inside Drive a new water pump shaft inside bearing into the water pump assembly from the inside Outer Bearing Inside Bearing Drive in a new mechanical seal using a mechanical seal driver Apply sealant the right crankcase cover fitting surface of a new mechanical seal and then drive in the mechanical seal Mechanical Seal Install the water pump shaft into the water
99. r wear and damage INSTALLATION Apply a small amount of grease to the starter pinion teeth Install the starter pinion in the reverse order of removal Starter Pinion 7 10 7 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY SUPER9 50 CLUTCH DRIVEN PULLEY CLUTCH DRIVEN PULLEY REMOVAL Remove the drive pulley 7 6 Hold the clutch outer with the universal holder and remove the 14mm clutch outer nut Remove the clutch outer Universal Holder Remove the clutch driven pulley Clutch Driven Pulley Remove the drive belt from the clutch driven pulley CLUTCH DRIVEN PULLEY Lock Nut Wrench 28mm DISASSEMBLY Compress the clutch driven pulley spring with the clutch spring compressor and remove the 28mm drive plate nut Remove the driven face spring Clutch Spring Compressor 7 11 7 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY SUPER OT E Remove the seal collar Seal Collar Pull out the guide roller pins from the Driven Pulley Oil Seal driven pulley and then remove the O rings and oil seal from the driven pulley O rings Guide Roller Pin CLUTCH DRIVEN PULLEY INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer Service Limit 107 5mm replace if over SF10DA 107 5mm replace if over 7 12 7 KICK STARTER DRIVE PULLEY QC KYMCO CLUTCH DRIVEN PULLEY SE Check the clutch shoes for wear da
100. retor cap and throttle valve spring Connect the throttle cable to the throttle valve Throttle Cable 12 3 KYMCO 12 CARBURETOR SUPER9 50 Groove Install the throttle valve by aligning the groove in the throttle valve with the throttle stop screw Throttle Stop Screw Tighten the carburetor cap Carburetor Cap After installation perform the following adjustments and inspections Throttle cable free play 43 12 Idle speed adjustment 3 11 Install the met in box Auto Bystarter Fuel Tube Throttle Cable CARBURETOR REMOVAL Remove the met in box 2 3 Remove the air cleaner by removing the air cleaner band screw and attaching bolts Disconnect the fuel tube Loosen the drain bolt to drain fuel from the carburetor Disconnect the auto bystarter wire connector Drain Bolt Band KYMCO 12 CARBURETOR SUPER9 50 Remove the two carburetor lock nuts Remove the carburetor and water hose AUTO BYSTARTER AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals Resistance 5Q 10 minutes minimum after stopping the engine If the resistance exceeds 5Q replace the auto bystarter with a new one After the engine stops for 30 minutes connect a hose to the fuel enriching circuit and blow the hose with mouth If air cannot be blown into the hose clogged the auto bystarter is faulty Replace it with a new one 12 5
101. stall the spring together with the 1st rubber cup During assembly the main piston and spring must be installed as a unit without exchange e When assembling the piston soak the cups in brake fluid for a while e Install the cups with the cup lips facing the correct direction Install the main piston spring and snap ring Install the rubber cover Install the brake lever b Snap Ring Rubber Cover Master Cylinder Spring Main Piston 13 9 13 STEERING HANDLEBAR FRONT WHEELFRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 Place the brake master cylinder on the handlebar and install the holder with the up mark facing up Also align the punch mark with the holder joint seam First tighten the upper bolt and then tighten the lower bolt Torque 9 8 13 72N m Fluid Tube Bolt Up Mark Install the brake fluid tube with the attaching bolt and two sealing washers Connect the front stop switch wire connector Install the handlebar covers 2 7 Stop Switch Wire Connector BRAKE FLUID REFILLING Keep the handlebar upright and remove the brake reservoir cover and diaphragm Add DOT 3 brake fluid to the brake reservoir When bleeding be careful not allow air in the brake reservoir flowing into the brake system e When using a brake bleeder follow the manufacturer s instructions e Never use dirty or unspecified brake fluid or mix different brake fluids
102. th adjacent or surrounding parts in all steering positions B When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions E Be careful not to drop any parts B When rust is found on a terminal remove the rust with sand paper or equivalent before connecting instrument Is the instrument set emove Rust f KYMCO SUPER9 50 1 10 1 GENERAL INFORMATION B Symbols The following symbols represent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use Engine Oil designated engine oil for lubrication gem Grease Apply grease for lubrication Transmission Gear Oil Gear Oil 90 29 Use special tool Special Caution Warning 1 11 KYMCO SUPER9 50 KYMCO 1 GENERAL INFORMATION SUPER9 50 SERVICE INFORMATION e Cylnderheadwapage f 38 90 Cylinder to piston clearance 003 007 12 03 11 98 0 40 17 03 39 05 19 97 Movable driven Lu 3406 lt Comesingrabigendsidedewmnee lt e Connecting rod big end radial clearance e ow e Crankshaft runout aB sg lt ORELOR Identification number Float level 8 6mm 8 6mm Jet needle clip notch 1 12 KYMCO 1
103. then install the throttle grip Connect the throttle cable to the throttle grip Install the right and left handlebar switches and tighten the screws Adjust grip free play to the specified range of 2 6mm Install the front and rear brake master Brake Master Cylinder cylinders Install brake master cylinders by aligning the index marks 13 STEERING HANDLEBARFRONT WHEELFRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 FRONT WHEEL REMOVAL Jack the motorcycle front wheel off the ground Remove the front axle nut to pull out the axle Remove the front wheel and the speedometer gear unit Axle Nut Speedometer Gear Unit INSPECTION AXLE RUNOUT Set the axle in V blocks and measure the runout using a dial gauge The actual runout is of the total indicator reading Service Limit 0 2mm replace if over WHEEL RIM Check the wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over 13 5 13 STEERING HANDLEBAR FRONT WHEELIFRONT O KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 FRONT WHEEL BEARING Remove the side collar and dust seal Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly Also check if the outer race fits tightly in the hub Replace the bearings if the races do not turn smoothly quietly or if they fit loosely in the hub Wheel Bearing BEARING R
104. ther cooling system service can be done with the engine installed in the frame e The engine must be cool before servicing the cooling system When the coolant temperature is over 100 C never remove the radiator cap to release the pressure because the boiling coolant may cause danger e Avoid spilling coolant on painted surfaces because the coolant will corrode the painted surfaces Wash off any spilled coolant with fresh water as soon as possible e After servicing the system check for leaks with a cooling system tester SPECIAL TOOL Mechanical seal driver TORQUE VALUES Water pump impeller 9 8 13 72N m Water pump cover bolt 7 84 11 76N m TROUBLESHOOTING Engine temperature too high Coolant leaks e Faulty temperature gauge or thermosensor e Faulty pump mechanical water seal e Faulty radiator cap Deteriorated O rings e Faulty thermostat e Damaged or deteriorated water hoses e Insufficient coolant e Passages blocked in hoses or water jacket e Clogged radiator fins e Passages blocked in radiator e Faulty water pump Temperature gauge pointer does not register the correct coolant temperature e Faulty temperature gauge or thermosensor e Faulty thermostat 11 1 KYMCO 11 COOLING SYSTEM SUPER9 50 SPECIFICATIONS 8022C Thermostat temperature Full open EEN Valve lift 3 5 4 5mm Coolant capacity Total system 1165 COOLANT GRAVITY concentration 1035 COOLANT MIXTURE WITH
105. too low 6V max Faulty CDI unit Lack of power e Weak battery e Loose wire or connection e Foreign matter stuck in starter motor or pinion Starter motor rotates but engine does not start e Faulty starter pinion e Starter motor rotates reversely e Faulty starter clutch Weak battery 15 2 15 ELECTRICAL EQUIPMENT SUPER9 50 Y Y I W vw gt T Pulser REG RECT Coil CHARGING SYSTEM A C Generator i alen 7 Ss lOjsIsow II 15 3 15 ELECTRICAL EQUIPMENT BATTERY BATTERY REMOVAL Open the front tool box and remove the bolt Remove the front tool box 52 4 Disconnect the battery cables First disconnect the battery negative cable and then the positive cable Remove the bolt and battery bracket Remove the battery The installation sequence is the reverse of removal BATTERY CHARGING OPEN CIRCUIT VOLTAGE INSPECTION Remove the battery cover and disconnect the battery cables Measure the voltage between the battery terminals Fully charged 13 0V 13 2 Undercharged 12 3V max gt Battery charging inspection must be performed with an electric tester CHARGING METHOD Connect the charger positive cable to the battery positive cable Connect the charger negative cable to the battery negative cable e Keep flames sparks away from charging battery e Turn power ON OFF at the charger not at th
106. tor jets Correct timing Incorrect timing 1 25 Correctly adjusted Incorrectly adjusted Faulty CDI unit generator Q A C G flywheel not aligned O Mixture too rich turn screw out Mixture too lean turn screw in KYMCO 1 GENERAL INFORMATION SUPER9 50 Inspection Adjustment Symptom Probable Cause Check carburetor gasket for air leaks 4 r Carburetor not securely tightened No air leak Air leaks 9 Faulty intake manifold gasket Deformed or broken carburetor O ring Remove auto bystarter connecting wire and check if bypass fuel line is clogged Broken cable Not clogged Clogged Q Dirty auto bystarter Faulty auto bystarter Connect auto bystarter wire to battery Wat for 5 minutes then connect a hose to fuel enriching gt circuit and then blow the hose with mouth Clogged Not Clogged Faulty auto bystarter 1 26 1 GENERAL INFORMATION ENGINE LACKS POWER Inspection Adjustment Symptom KYMCO SUPER9 50 Probable Cause Start engine and accelerate lightly for observation Engine speed increases Check ignition timing using
107. unit wire Check connectors for proper connection O Loose or disconnected Good Faulty connector Incorrectly connected connector 2 Pointer fluctuates or swings Ignition switch ON Inspection Adjustment Check battery circuit by operating turn signals and horn Symptom Broken or shorted wire in fuel gauge Probable Cause O Burned out fuse Remove fuel unit and check operation of pointer by moving float up and down Signals operate properly Signals dim remain don t operate Weak or dead battery Faulty ignition switch Loose or disconnected gt connector Broken wire harness Move float up and down rapidly 1 round sec to check the operation of pointer Pointer moves Pointer does not move Poor contact in fuel unit Check connectors for proper connection Pointer moves in accordance with float Pointer does not move in accord ance with float O Insufficient damping oil in fuel gauge 1 33 Good Faulty n O Loose or disconnected connector Broken or shorted wire in fuel gauge KYMCO 1 GENERAL INFORMATION SUPER9 50
108. ut 14 7 24 5N m apply locking agent Rear brake caliper bolt 19 6 29 4N m TROUBLESHOOTING Rear wheel wobbling Poor brake performance e Bent rim e Air in brake system e Faulty tire Deteriorated brake fluid e Axle not tightened properly e Contaminated brake pad surface e Worn brake pads Soft rear shock absorber e Clogged brake fluid line Weak shock absorber spring e Deformed brake disk Damper oil leaks e Unevenly worn brake caliper Rear wheel noise e Worn rear wheel axle bearings e Worn rear fork bearings e Deformed rear fork 14 1 14 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER SUPER9 50 _ REAR BRAKE SH10DA Brake Caliper 100 Bolt REAR BRAKE CALIPER REMOVAL First remove the exhaust muffler 2 6 Remove the rear brake fluid tube bolt and disconnect the brake fluid tube Remove the two bolts attaching the rear brake caliper Remove the rear brake caliper When removing brake fluid tube use shop towels to cover plastic parts and coated surfaces to avoid damage INSPECTION Inspect the brake pads and brake disk Visually check the brake pad thickness and it should not exceed the wear indicator mark Measure the brake disk thickness Service Limit 3 0mm replace if below DISASSEMBLY Disassemble the rear brake caliper 14 11 Inspect and assemble the rear brake caliper gt 14 12 Note The rear brake caliper and front brake caliper have the same speci
109. valve Too much fuel getting to cylinder e Clogged fuel cap vent Float level too low Clogged fuel filter Clogged fuel filter Clogged air cleaner Clogged air cleaner e Bent kinked or restricted fuel line Engine idles roughly stalls or runs poorly Rich mixture e Incorrect idle speed e Clogged air cleaner e Faulty float valve e Ignition malfunction e Intake air leaks Float level too high e Compression too low e Fuel contaminated Clogged air jets Incorrectly adjusted air screw e Faulty reed valve Incorrect float level e Clogged fuel jets 12 1 KYMCO 12 CARBURETOR SUPER9 50 THROTTLE VALVE DIS ASSEMBLY Remove the rear carrier 42 3 Remove the met in box 52 4 Loosen the carburetor cap and remove the throttle valve Carburetor Cap Throttle Valve Disconnect the throttle cable from the throttle valve Rubber Seal Carburetor Cap Remove the throttle valve spring carburetor cap and rubber seal 12 2 KYMCO 12 CARBURETOR SUPER9 50 Remove the jet needle by removing the Throttle Valve needle clip Check the jet needle and throttle valve for wear or damage Needle Clip Spring Jet Needle THROTTLE VALVE INSTALLA EE Carburetor Install the jet needle on the throttle valve and secure with the needle clip Throttle Valve Spring Install the rubber seal on the throttle cable Throttle Valve and then install the carbu
110. ve the motorcycle frame covers before removing the front wheel steering handlebar front shock absorber and front fork Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down e During servicing keep oil or grease off the brake pads and brake disk SPECIFICATIONS Standard mm Axle shaft runout 0 2 Geesen E Axial 2 Front brake pad thickness Front shock absorber spring free length 221 5 204 3 Brake disk runout C8 TORQUE VALUES Steering stem lock nut 78 4 117 6N m Steering top cone race 4 9 12 74N m Front shock absorber bolt 19 6 24 5N m Front axle nut 44 49 0N m Brake caliper bolt 24 5 34 3N m SPECIAL TOOLS Lock nut wrench Front shock absorber compressor Ball race remover Driver handle Outer driver Bearing remover Bearing remover head 12mm 13 1 13 STEERING HANDLEBARFRONT WHEELFRONT O KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK SUPER 9 50 TROUBLESHOOTING Hard steering heavy e Excessively tightened steering stem top cone race e Broken steering balls e Insufficient tire pressure Steers to one side or does not track straight e Uneven front shock absorbers e Bent front fork e Bent front axle or uneven tire Poor brake performance e Worn brake pads e Contaminated brake pad surface e Deformed brake disk e Air in brake system e Deteriorated brake fluid e Worn brake master cylinder piston oil seal e Clogged brake flui
111. xhaust muffler e Exhaust muffler air leaks 2 1 KYMCO 2 EXHAUST MUFFLER FRAME COVERS SUPER9 50 FRAME COVERS REMOVAL Bolts Nuts screws REAR CARRIER amp HAND RAIL REMOVAL Remove the met in box First remove the two bolts and two nuts and front two screws attaching the met in box Remove the met in box Hex Bolt Remove the three hex bolts attaching the rear 2 carrier Remove the rear carrier and rear center cover Rear Center Cover Bottom Cover FRAME BODY COVER REMOVAL Remove the four screws attaching on the bottom of the frame body cover Remove the bottom cover Screws KYMCO 2 EXHAUST MUFFLER FRAME COVERS SUPER9 50 Remove the right and left screws and bolt on Frame Body Cover the rear part of the frame body cover Disconnect the air cleaner case of the air entrance tube Remove the frame body cover Air Entrance Tube Screw FRONT UPPER COVER REMOVAL Remove the two screws on the back of the front upper cover Remove the front upper cover The installation sequence is the reverse of removal GEN Front Upper Cover Screws FRONT LOWER COVER REMOVAL First remove the front upper cover Remove the six screws and two bolts attaching the front lower cover Remove the six screws on the back of the front lower cover Disconnect the headlight wire connectors Remove the front lower cover The installation sequence is the reverse of removal Screws 2

Kymco Super 9 (SH10DA) servicemanual

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