Table Of Contents - KYMCO SUPER 9 50 Service Manual

Table of Contents

Table Of Contents1
General Information3
Engine Serial Number3
Vehicle Identification Serial Number3
Location Of Engine Serial Number3
Super3
Specifications4
Service Precautions6
Service Information14
Torque Values16
Special Tools17
Lubrication Points18
Frame18
Wiring Diagram24
Troubleshooting26
Engine Will Not Start Or Is Hard To Start26
Engine Stops Immediately After It Starts27
Engine Lacks Power29
Inspection/Adjustment29
Poor Performance (Especially At Idle And Low Speeds)30
Poor Performance (At High Speed)31
Clutch, Drive And Driven Pulleys32
Steering Handlebar Does Not Track Straight32
Poor Suspension Performance33
Poor Brake Performance33
Oil Meter34
Fuel Gauge35
Pointer Does Not Register Correctly35
Pointer Fluctuates Or Swings35
Starter Motor36
Starter Motor Won't Turn36
Starter Motor Turns Slowly Or Idles36
Starter Motor Does Not Stop Turning36
Exhaust Muffler/Frame Covers37
Lack Of Power38
Frame Covers Removal39
Rear Carrier & Hand Rail Removal39
Frame Body Cover Removal39
Front Upper Cover Removal40
Front Lower Cover Removal40
Leg Shield Removal41
Front Tool Box Removal41
Floor Board Removal42
Bottom Cover Removal43
Front Inner Fender Removal43
Exhaust Muffler Removal43
Handlebar Cover Removal44
Lubrication Oil Capacity46
Gear Oil Capacity46
Tire Specification46
Inspection And Maintenance Schedule47
Fuel Line/Fuel Filter50
Throttle Operation50
Air Cleaner51
Change Interval51
Spark Plug52
Ignition Timing52
Cylinder Compression53
Final Reduction Gear Oil54
Oil Change54
Drive Belt54
Headlight Aim55
Cooling System55
Coolant Level Inspection55
Coolant Replacement55
Brake System56
Brake Lever56
Brake Fluid57
Brake Disk/Brake Pad57
Brake Drum/Shoe57
Nuts/Bolts/Fasteners58
Wheels/Tires58
Steering Handlebar58
Suspension58
Lubrication System59
Oil Filter Cleaning59
Oil Pump Condition59
Excessive White Smoke Or Carbon Deposits On Spark Plug61
Engine Overheating61
Seized Piston61
Oil Not Flowing Out Of Tank To Engine61
Oil Pump Removal62
Oil Pump Inspection62
Oil Pump Installation63
Oil Pump Bleeding64
Oil Inlet Line/Oil Pump Bleeding64
Oil Outlet Line Bleeding64
Oil Tank Removal65
Engine Removal/Installation66
Engine Removal68
Engine Hanger Bracket Removal69
Engine Hanger Bracket Inspection70
Engine Installation70
Cylinder Head/Cylinder/Piston71
Compression Too Low, Hard Starting Or Poor Performance At Low Speed72
Compression Too High, Overheating Or Knocking72
Abnormal Noisy Piston72
Abnormal Noisy Piston Rings72
Cylinder Head Removal73
Cylinder Head74
Combustion Chamber Decabonizing75
Cylinder Head Inspection75
Cylinder Head Installation75
Cylinder Head Bolts Installation76
Engine Hood Installation76
Cylinder/Piston77
Cylinder Removal77
Piston Removal77
Cylinder/Piston Inspection78
Piston Ring Inspection80
Connecting Rod Small End Inspection80
Piston/Cylinder Installation80
Kick Starter/Drive Pulley/Clutch/Driven Pulley82
Engine Starts but Motorcycle Won't Move83
Engine Stalls Or Motorcycle Creeps83
Poor Performance At High Speed Or Lack Of Power83
Kick Starter84
Left Crankcase Cover Removal84
Kick Starter Spindle Removal84
Kick Starter Spindle Inspection85
Kick Starter Installation86
Left Crankcase Cover Installation87
Drive Belt Inspection88
Drive Belt Replacement88
Drive Belt Installation89
Drive Pulley Removal90
Movable Drive Face Disassembly90
Movable Drive Face Inspection91
Drive Pulley Installation91
Starter Pinion Removal92
Starter Pinion Inspection92
Starter Pinion Installation92
Clutch/Driven Pulley Removal93
Clutch/Driven Pulley Disassembly93
Clutch/Driven Pulley Inspection94
Driven Pulley Face Bearing Replacement96
Clutch/Driven Pulley Assembly97
Clutch/Driven Pulley Installation98
Final Reduction99
Abnormal Noise100
Oil Leaks100
Final Reduction Disassembly101
Final Reduction Inspection101
Bearing Replacement103
Final Reduction Assembly104
A.c. Generator107
A.c. Generator Removal109
A.c. Generator Installation112
Crankcase/Crankshaft113
Abnormal Engine Noise114
Crankcase Separation115
Crankshaft Removal115
Crankshaft Inspection116
Crankshaft Installation117
Crankcase Assembly119
Engine Temperature Too High122
Temperature Gauge Pointer Does Not Register122
Coolant Leaks122
Coolant Gravity123
Coolant Mixture (With Anti-Rust And Anti-Freezing Effects)123
Radiator Inspection124
Radiator Removal124
Radiator Bracket Removal/Installation126
Radiator Installation126
Water Pump127
Mechanical Seal (Water Seal) Inspection127
Water Pump/Impeller Removal128
Water Pump Shaft Removal129
Water Pump Bearing/Mechanical Seal Removal130
Water Pump Bearing/Mechanical Seal Installation131
Water Pump/Impellerinstallation132
Thermosensor Removal133
Thermosensor Inspection133
Thermosensor Installation133
Thermostat Removal134
Thermostat Inspection134
Thermostat Installation135
Carburetor136
Engine Does Not Start137
Engine Idles Roughly, Stalls Or Runs Poorly137
Lean Mixture137
Rich Mixture137
Throttle Valve Disassembly138
Throttle Valve Installation138
Carburetor Removal140
Auto Bystarter Inspection141
Auto Bystarter Removal142
Auto Bystarter Installation143
Float Chamber143
Float/Float Valve Inspection144
Jets/Screws Removal144
Carburetor Passages Cleaning144
Float Chamber Assembly145
Float Level Inspection145
Carburetor Installation146
Air Screw Adjustment146
Reed Valve Removal147
Reed Valve Inspection147
Reed Valve Installation147
Steering Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Front Fork148
Hard Steering (Heavy)150
Steers To One Side Or Does Not Track Straight150
Front Wheel Wobbling150
Soft Front Shock Absorber150
Steering Handlebar Removal151
Steering Handlebar Installation152
Front Wheel Removal153
Front Wheel Inspection153
Axle Runout153
Wheel Rim153
Front Wheel Bearing154
Front Brake156
Brake Master Cylinder Removal156
Brake Master Cylinder Disassembly156
Brake Fluid Refilling158
Brake Fluid Bleeding159
Brake Caliper Removal159
Brake Caliper Disassembly159
Front Shock Absorber Removal162
Front Shock Absorber Disassembly162
Front Fork162
Front Shock Absorber Inspection163
Front Shock Absorber Assembly164
Front Shock Absorber Installation165
Front Fork Removal166
Bottom Cone Race Replacement166
Ball Race Replacement167
Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber169
Rear Wheel Wobbling170
Soft Rear Shock Absorber170
Rear Wheel Noise170
Rear Brake Caliper Removal171
Rear Fork (Sf10Da) Removal172
Rear Wheel Removal172
Rear Brake Drum174
Brake Lining Inspection174
Rear Brake Disassembly174
Rear Brake Assembly175
Rear Shock Absorber Removal176
Rear Shock Absorber Disassembly177
Rear Shock Absorber Inspection177
Rear Shock Absorber Assembly178
Rear Shock Absorber Installation178
Electrical Equipment179
No Power180
Low Power180
Intermittent Power180
Charging System Failure180
Battery180
No Spark At Plug181
Engine Starts But Turns Poorly181
Ignition System181
Starting System181
Battery Removal183
Battery Charging (Open Circuit Voltage) Inspection183
Charging Method183
Performance Test184
A.c. Generator (Charging Coil) Inspection184
Resistor Inspection185
Regulator/Rectifier Inspection185
Ignition Coil Inspection187
Continuity Test187
Exciter Coil/Pulser Coil Inspection188
Cdi Unit Inspection189
Cdi Circuit Inspection189
Starter Relay Inspection191
Starter Motor Removal191
Starter Motor Inspection192
Instrument/Switches/Lights193
Lights Do Not Come on When Ignition Switch Is "ON"194
Light Dims194
Headlight Does Not Change When Dimmer Switch Is Turn To Hi Or Lo194
Motor Oil Indicator Light Does Not Come On194
Fuel Unit Removal195
Fuel Unit Inspection195
Fuel Gauge Inspection195
Fuel Gauge Installation196
Oil Meter Inspection196
Oil Meter Operation Inspection196
Ignition Switch Inspection197
Ignition Switch Replacement197
Switches197
Headlight Switch Inspection198
Dimmer Switch Inspection198
Turn Signal Switch Inspection198
Starter Switch Inspection199
Horn Switch Inspection199
Stop Switch Inspection199
Horn Inspection200
Front Turn Signal Light Replacement200
Taillight/Stoplight/Rear Turn Signal Light Bulb Replacement200
Instrument Bulbs Replacement201
Speedometer Removal201
Headlight Removal/Bulb Replacement201
Evaporative/Exhaust Emission Control System202
Exhaust Emission Control System203
Exhaust Muffler Diagram203
Lack Of Power And High Co & Ho203
Engine Runs Erratic At Idle Speed And High Fuel Consumption203
Exhaust Muffler Inspection204
Exhaust Muffler Installation204
Exhaust Emission Related System Inspection205
Exhaust Emission Test And Adjustment205