KYMCO SUPER 9 50 Service Manual

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Owner's manual (46 pages)

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Table Of Contents

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Table of Contents

Quick Links

Troubleshooting

Summary of Contents for KYMCO SUPER 9 50

Page 1 TABLE OF CONTENTS GENERAL INFORMATION This Service Manual describes the technical features and servicing EXHAUST MUFFLER/FRAME COVERS procedures for the KYMCO Super9 50. INSPECTION/ADJUSTMENT LUBRICATION SYSTEM Section 1 contains the precautions for all operations stated in this manual. ENGINE REMOVAL/INSTALLATION...
Page 2 . GENERAL INFORMATION SUPER 9 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ ENGINE SERIAL NUMBER ---------------------------------------------- 1- 1 SPECIFICATIONS ---------------------------------------------------------- 1- 2 SERVICE PRECAUTIONS ------------------------------------------------ 1- 4 TORQUE VALUES --------------------------------------------------------- 1-14 SPECIAL TOOLS ----------------------------------------------------------- 1-15 LUBRICATION POINTS -------------------------------------------------- 1-16 WIRING DIAGRAM-------------------------------------------------------- 1-22 TROUBLESHOOTING----------------------------------------------------- 1-24...
Page 3: Super
. GENERAL INFORMATION SUPER 9 ENGINE SERIAL NUMBER Vehicle Identification Serial Number Location of Engine Serial Number Location of Frame Serial Number...
Page 4: Specifications ----------------------------------------------------------
. GENERAL INFORMATION SUPER 9 SPECIFICATIONS Air cleaner type & No Sponge wet Name & Model No. SH10DA Gear oil capacity 0.12 liters Overall length 1850mm Fuel capacity 6.8 liters Overall width 700mm ＰＢ Type Overall height 1190mm Piston dia. Wheel base 1295mm Venturi dia.
Page 5 . GENERAL INFORMATION SUPER 9 Air cleaner type & No Sponge wet Name & Model No. SF10DA Gear oil capacity 0.12 liters Overall length 1850mm Fuel capacity 6.8 liters Overall width 700mm ＰＢ Type Overall height 1190mm Piston dia. Wheel base 1295mm Venturi dia.
Page 6: Service Precautions
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. KYMCO KYMCO KYMCO When servicing the motorcycle, be sure to use special tools for removal and installation.
Page 7 After reassembly, check all parts for proper tightening and operation. When two persons work together, pay attention to the mutual working safety. KYMCO Disconnect the battery negative (-) terminal before operation. When using a spanner or other tools, make sure not to damage the motorcycle surface.
Page 8 . GENERAL INFORMATION SUPER 9 If the fuse is burned out, find the cause Confirm and repair it. Replace it with a new one Capacity according to the specified capacity. After operation, terminal caps shall be installed securely. When taking out the connector, the lock on the connector shall be released before operation.
Page 9 . GENERAL INFORMATION SUPER 9 The connector shall be inserted completely. If the double connector has a lock, Snapping! lock it at the correct position. Check if there is any loose wire. Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
Page 10 . GENERAL INFORMATION SUPER 9 After clamping, check each wire to make sure it is secure. Do not squeeze wires against the weld or its clamp. After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
Page 11 . GENERAL INFORMATION SUPER 9 Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.
Page 12 . GENERAL INFORMATION SUPER 9 After routing, check that the wire harnesses are not twisted or kinked. Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.
Page 13 . GENERAL INFORMATION SUPER 9 Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for Engine Oil lubrication.) : Apply grease for Grease lubrication.
Page 14 . GENERAL INFORMATION SUPER 9 SERVICE INFORMATION ENGINE Standard (mm) Service Limit (mm) SF10DA SH10DA SF10DA SH10DA Item ⎯ ⎯ Cylinder head warpage 0.10 0.10 ～～ Piston O.D.(5mm from bottom of piston skirt) 38.955 38.970 38.955 38.970 38.90 38.90 Cylinder-to- piston clearance ～...
Page 15 . GENERAL INFORMATION SUPER 9 FRAME Standard (mm) Service Limit (mm) Item SF10DA SH10DA SF10DA SH10DA ⎯ ⎯ Axle shaft runout Radial Front wheel rim runout Axial Front shock absorber spring free length 221.5 221.5 204.3 204.3 Rear wheel rim runout Brake drum I.D.
Page 16: Torque Values
. GENERAL INFORMATION SUPER 9 TORQUE VALUES ENGINE Item Thread dia. (mm) Torque (N-m) Remarks Cylinder head bolt BF7x115 14.7～16.7 (cold) Clutch drive plate nut 34.3～39.2 Clutch outer nut NH10 34.3～44.1 Drive face nut NH12 49.0～58.8 Oil check bolt 9.8～14.7 Engine mounting bolt BF10x95 44.1～53.9...
Page 17: Special Tools
. GENERAL INFORMATION SUPER 9 SPECIAL TOOLS Tool Name Tool No. Remarks Universal bearing puller E030 Crankshaft bearing removal Lock nut socket wrench F001 Top cone race holding Lock nut wrench, F001 Stem lock nut tightening Crankcase puller E026 Crankcase disassembly Bearing remover set, 12mm Drive shaft bearing removal/installation E020...
Page 18: Lubrication Points
. GENERAL INFORMATION SUPER 9 LUBRICATION POINTS ENGINE Lubrication Points Lubricant Remarks Crankcase sliding & movable JASO-FC or API-TC Cylinder movable parts Transmission gear (final gear) SAE-90# Kick starter spindle bushing Grease Drive pulley movable parts Grease Starter pinion movable parts Grease FRAME Apply clean engine oil or grease to cables and movable parts not specified.
Page 19 . GENERAL INFORMATION SUPER 9 Brake Master Cylinders Rear Stop Switch Front Stop Switch Throttle Cable Speedometer Cable Water Hose Horn Reserve Cap Resistors Wire Harness Radiator 1-17...
Page 20 . GENERAL INFORMATION SUPER 9 Winker Ignition Switch Regulator/ Rectifier Water Hose Fuse Box CDI Unit Front Brake Fluid Tube Starter Relay 1-18...
Page 21 . GENERAL INFORMATION SUPER 9 Throttle Cable Reserve Cap Water Hose Speedometer Cable Wire Harness Rear Brake Control Cable 1-19...
Page 22 . GENERAL INFORMATION SUPER 9 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...
Page 23 . GENERAL INFORMATION SUPER 9 Ignition Coil Wire Harness Throttle Cable Water Hose Oil Tube Spark Plug Auto Bystarter Wire Oil Meter Fuel Pump Fuel Tube Fuel Filter Ignition Coil Fuel Unit Wire Air Injection Air Cleaner 1-21...
Page 24 . GENERAL INFORMATION SUPER 9 WIRING DIAGRAM 〈SF10DA〉 1-22...
Page 25 . GENERAL INFORMATION SUPER 9 〈SH10DA〉 1-23...
Page 26: Troubleshooting-----------------------------------------------------
. GENERAL INFORMATION SUPER 9 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw. Empty fuel tank Clogged float valve Fuel reaches Fuel does not Clogged charcoal canister carburetor reach carburetor Clogged fuel filter...
Page 27 . GENERAL INFORMATION SUPER 9 ENGINE STOPS IMMEDIATELY AFTER IT STARTS Inspection/Adjustment Symptom Probable Cause Check if fuel reaches carburetor by loosening drain screw. Empty fuel tank Clogged float valve Fuel does not Fuel reaches Clogged charcoal canister reach carburetor carburetor Clogged fuel filter Faulty auto fuel valve...
Page 28 . GENERAL INFORMATION SUPER 9 Inspection/Adjustment Symptom Probable Cause Check carburetor gasket for air leaks. Carburetor not securely tightened No air leak Air leaks Faulty intake manifold gasket Deformed or broken carburetor O-ring Remove auto bystarter connecting wire and check if bypass fuel line is clogged.
Page 29 . GENERAL INFORMATION SUPER 9 ENGINE LACKS POWER Inspection/Adjustment Symptom Probable Cause Start engine and accelerate lightly for observation. Clogged air cleaner Engine speed does Clogged fuel filter Engine speed not increase Clogged exhaust muffler increases sufficiently Faulty auto bystarter Faulty charcoal canister Check ignition timing (using a timing light).
Page 30 . GENERAL INFORMATION SUPER 9 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing. Faulty CDI unit Incorrect timing Correct timing Faulty A.C. generator Check carburetor air screw adjustment. Mixture too rich (turn screw Correctly adjusted Incorrectly adjusted out)
Page 31 . GENERAL INFORMATION SUPER 9 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing. Faulty CDI unit Correct timing Incorrect timing Loose A.C.G. stator Faulty A.C. generator Check auto fuel valve for fuel supply. Empty fuel tank Fuel flows freely Fuel flow restricted Clogged fuel tube or filter...
Page 32 . GENERAL INFORMATION SUPER 9 CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause Worn or slipping drive belt Broken ramp plate Broken driven face spring Engine starts but motor- Separated clutch lining cycle does not move Damaged driven pulley shaft splines Damaged final gear Seized final gear Motorcycle creeps or...
Page 33 . GENERAL INFORMATION SUPER 9 POOR SUSPENSION PERFORMANCE Symptom Probable Cause (Front and rear tire pressures are normal) Weak shock spring Suspension is too soft Excessive load Shock damper oil leaking Bent fork tube or shock rod Suspension is too hard Fork slider and tube binding Fork tube and spring binding Suspension is noisy...
Page 34 . GENERAL INFORMATION SUPER 9 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 operating turn signals. Burned out fuse Weak or dead battery Signals dim, remain Signals operate Faulty ignition switch...
Page 35: Fuel Gauge
. GENERAL INFORMATION SUPER 9 FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn signals. Burned out fuse Weak or dead battery Signals operate Signals dim, remain Faulty ignition switch properly on or don‘t operate Loose or disconnected...
Page 36: Starter Motor
. GENERAL INFORMATION SUPER 9 STARTER MOTOR 1. Starter motor won‘t turn Symptom Probable Cause Inspection/Adjustment Check operation of Burned out fuse stop switch by Weak or dead battery applying brake. Faulty stop switch Stoplight does not Stoplight comes on Loose or disconnected come on connector...
Page 37: Exhaust Muffler/Frame Covers
. EXHAUST MUFFLER/FRAME COVERS SUPER 9 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 2- 1 TROUBLESHOOTING----------------------------------------------------- 2- 1 FRAME COVERS REMOVAL ------------------------------------------- 2- 2 EXHAUST MUFFLER REMOVAL-------------------------------------- 2- 6...
Page 38 . EXHAUST MUFFLER/FRAME COVERS SUPER 9 SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged. • Make sure to route cables and harnesses according to the Cable & Harness Routing. TORQUE VALUES Exhaust muffler lock bolt 34.3N-m...
Page 39 . EXHAUST MUFFLER/FRAME COVERS SUPER 9 FRAME COVERS REMOVAL Bolts/Nuts screws REAR CARRIER & 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 Bolts Remove the three hex bolts attaching the rear carrier.
Page 40 . EXHAUST MUFFLER/FRAME COVERS SUPER 9 Frame Body Cover Remove the right and left screws and bolt on the rear part of the frame body cover. Disconnect the air cleaner case of the air entrance tube. Remove the frame body cover. Screw Air Entrance Tube FRONT UPPER COVER REMOVAL...
Page 41 . EXHAUST MUFFLER/FRAME COVERS SUPER 9 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.
Page 42 . EXHAUST MUFFLER/FRAME COVERS SUPER 9 Remove the center cover by pulling them backward. Remove the center cover. Center Cover Bolts FLOOR BOARD REMOVAL Remove the screw and two bolts attaching the front right and left side covers. Remove the two bottom cover attaching screws.
Page 43 . EXHAUST MUFFLER/FRAME COVERS SUPER 9 Screws BOTTOM COVER REMOVAL Remove the four screws attaching the bottom cover and inner bottom cover. Remove the bottom cover. Bottom Cover FRONT INNER FENDER REMOVAL Remove the front upper cover. ( 2-3) Fender Remove the front lower cover.
Page 44 . EXHAUST MUFFLER/FRAME COVERS SUPER 9 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.
Page 45 . INSPECTION/ADJUSTMENT SUPER 9 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 3- 1 INSPECTION AND MAINTENANCE SCHEDULE ------------------ 3- 2 FUEL LINE/FUEL FILTER------------------------------------------------ 3- 5 THROTTLE OPERATION------------------------------------------------- 3- 5 AIR CLEANER -------------------------------------------------------------- 3- 6 SPARK PLUG---------------------------------------------------------------- 3- 7 IGNITION TIMING--------------------------------------------------------- 3- 7 CYLINDER COMPRESSION --------------------------------------------- 3- 8 FINAL REDUCTION GEAR OIL ---------------------------------------- 3- 9...
Page 46: Inspection/Adjustment
. INSPECTION/ADJUSTMENT SUPER 9 SERVICE INFORMATION GENERAL ！ WARNING •Before 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. •Gasoline is extremely flammable and is explosive under some conditions.
Page 47: Inspection And Maintenance Schedule
. INSPECTION/ADJUSTMENT SUPER 9 INSPECTION AND MAINTENANCE SCHEDULE (Note) 1. ○means time for inspection. 2. ☆means 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.
Page 48 . INSPECTION/ADJUSTMENT SUPER 9 Frequency Inspection & Maintenance Item Judgment Standards Remarks Every 6 Every 12 Preride month months months ○ ○ ○ Tire crack and damage Groove Depth: Tire groove and ○ ○ ○ Front: 0.8mm abnormal wear Rear : 0.8mm Imbedded objects, ○...
Page 49 . INSPECTION/ADJUSTMENT SUPER 9 Frequency Inspection & Maintenance Item Judgment Standards Remarks Every 6 Every 12 Preride month months months Performance and abnormal ○ ○ noise Conditions at low and high ○ ○ ○ Body speeds ○ ○ Exhaust smoke ○...
Page 50: Throttle Operation
. INSPECTION/ADJUSTMENT SUPER 9 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. ＊...
Page 51: Air Cleaner
. INSPECTION/ADJUSTMENT SUPER 9 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 air cleaner case cover screws and the cover.
Page 52 . INSPECTION/ADJUSTMENT SUPER 9 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: NGK: BR8HSA 0.6～0.7mm...
Page 53: Cylinder Compression
. INSPECTION/ADJUSTMENT SUPER 9 “F” Mark Check the ignition timing with a timing light. When the engine is running at the specified idle speed, the ignition timing is correct if the “F” mark on the flywheel aligns with the index mark on the crankcase cover. Also use a timing light to check the advance.
Page 54 . INSPECTION/ADJUSTMENT SUPER 9 Oil Check Bolt Hole/Oil Filler FINAL REDUCTION GEAR OIL ＊ • Place the motorcycle on its main stand on level ground. Stop the engine and remove the oil check bolt. The oil level shall be at the oil check bolt hole.
Page 55: Headlight Aim
. INSPECTION/ADJUSTMENT SUPER 9 HEADLIGHT AIM Turn the ignition switch ON. Turn on the headlight switch. Adjust the headlight aim by turning the headlight aim adjusting bolt. Headlight Aim Adjusting Bolt COOLING SYSTEM Upper Line COOLANT LEVEL INSPECTION Place the motorcycle on its main stand on level ground.
Page 56: Brake System
. INSPECTION/ADJUSTMENT SUPER 9 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.
Page 57 . INSPECTION/ADJUSTMENT SUPER 9 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 ＊...
Page 58: Steering Handlebar
. INSPECTION/ADJUSTMENT SUPER 9 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. ＊...
Page 59: Lubrication System
. INSPECTION/ADJUSTMENT SUPER 9 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.
Page 60 . LUBRICATION SYSTEM SUPER 9 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION ..............4-1 TROUBLESHOOTING ............... 4-1 OIL PUMP REMOVAL............... 4-2 OIL PUMP INSPECTION ..............4-2 OIL PUMP INSTALLATION ............. 4-3 OIL PUMP BLEEDING............... 4-4 OIL TANK ................... 4-5...
Page 61 . LUBRICATION SYSTEM SUPER 9 SERVICE INFORMATION GENERAL INSTRUCTIONS • Use care when removing and installing the oil pump not to allow dust and dirt to enter the engine and oil line. • Do not attempt to disassemble the oil pump. •...
Page 62: Oil Pump Removal
. LUBRICATION SYSTEM SUPER 9 Oil Pump Control Cable OIL PUMP REMOVAL ＊ Do not allow foreign matters to enter the crankcase. Before removing the oil pump, clean the oil pump and crankcase surfaces. Remove the met-in box. ( 2-2) Oil Inlet Line Oil Outlet Line Disconnect the oil pump control cable from...
Page 63 . LUBRICATION SYSTEM SUPER 9 OIL PUMP INSTALLATION ＊ • Lubricate the O-ring with grease or engine oil before installation. • Make sure that the oil pump is inserted into the crankcase. • Apply molybdenum disulfide or grease to the pump pinion. Grease or Engine Oil Install the oil pump onto the crankcase.
Page 64 . LUBRICATION SYSTEM SUPER 9 OIL PUMP BLEEDING Oil Pump Oil Outlet Line ＊ • Air in the oil lines will block oil flow and result in severe engine damage. • 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.
Page 65: Oil Tank
. LUBRICATION SYSTEM SUPER 9 Oil Meter OIL TANK 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.
Page 66: Engine Removal/Installation
. ENGINE REMOVAL/INSTALLATION SUPER 9 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION ..............5-1 ENGINE REMOVAL ................5-2 ENGINE INSTALLATION ..............5-4...
Page 67 . ENGINE REMOVAL/INSTALLATION SUPER 9 SERVICE INFORMATION GENERAL INSTRUCTIONS • Parts requiring engine removal for servicing: Crankcase Crankshaft TORQUE VALUES Engine mounting bolt 44.1～53.9N-m Engine hanger bracket bolt 44.1～53.9N-m Rear shock absorber lower mount bolt 23.5～29.4N-m Rear shock absorber upper mount bolt 34.3～44.1N-m...
Page 68: Engine Removal
. ENGINE REMOVAL/INSTALLATION SUPER 9 Clamp ENGINE REMOVAL Remove the frame body cover. ( 2-2) 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 Oil Inlet Line Auto Fuel Valve...
Page 69 . ENGINE REMOVAL/INSTALLATION SUPER 9 Band Air Cleaner Case Carburetor Cap 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.
Page 70 . ENGINE REMOVAL/INSTALLATION SUPER 9 Engine Hanger ENGINE HANGER BRACKET 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. ＊...
Page 71: Cylinder Head/Cylinder/Piston
. CYLINDER HEAD/CYLINDER/PISTON SUPER 9 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/CYLINDER/PISTON __________________________________________________________________________________ SERVICE INFORMATION ..............6-1 TROUBLESHOOTING ............... 6-1 CYLINDER HEAD................6-2 CYLINDER/PISTON................6-6...
Page 72 . CYLINDER HEAD/CYLINDER/PISTON SUPER 9 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head, cylinder and piston can be serviced with the engine installed in the frame. • Before disassembly, clean the engine to prevent dust from entering the engine. • Remove all gasket material from the mating surfaces. •...
Page 73: Cylinder Head
. CYLINDER HEAD/CYLINDER/PISTON SUPER 9 Spark Plug Cap CYLINDER HEAD REMOVAL 〈SH10AD〉 Remove the rear carrier. Remove the frame body cover. ( 2-2) Drain the coolant. Disconnect the thermosensor wire from the thermosensor. Disconnect the water hose from the thermostat housing. Exhaust muffler joint lock nut Remove the spark plug cap.
Page 74 . CYLINDER HEAD/CYLINDER/PISTON SUPER 9 Spark Plug Cap CYLINDER HEAD REMOVAL　〈SF10DA〉 Remove the rear carrier. Remove the frame body cover. ( 2-2) Fan Cover/Engine Hood 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 two exhaust muffler lock bolts.
Page 75 . CYLINDER HEAD/CYLINDER/PISTON SUPER 9 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.
Page 76 . CYLINDER HEAD/CYLINDER/PISTON SUPER 9 Cylinder head Bolts Cylinder Head Bolts Installation 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 Spark Plug Engine Hood Engine Hood Installation Install the engine hood.
Page 77 . CYLINDER HEAD/CYLINDER/PISTON SUPER 9 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.
Page 78 . CYLINDER HEAD/CYLINDER/PISTON SUPER 9 CYLINDER/PISTON INSPECTION Check the cylinder and piston for wear or damage. Clean carbon deposits from the exhaust port area. ＊ Be careful not to damage the cylinder inside wall. Measure the cylinder bore at three levels of A, B and C in both X and Y directions.
Page 79 . CYLINDER HEAD/CYLINDER/PISTON SUPER 9 ＊ The cylinder has an A mark or no mark on it. 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.
Page 80 . CYLINDER HEAD/CYLINDER/PISTON SUPER 9 Feeler Gauge Piston Ring PISTON RING INSPECTION Measure each piston ring end gap. Service Limits: Top/Second SH10DA: 0.40mm replace if over SF10DA: 0.40mm replace if over ＊ Set each piston ring squarely into the cylinder using the piston and measure the end gap.
Page 81 . CYLINDER HEAD/CYLINDER/PISTON SUPER 9 Install a new cylinder gasket on the mating Cylinder Gasket surface between the cylinder and crankcase. Ring Pins Make sure that the ring end gaps are aligned with the piston ring pins in the ring grooves.
Page 82: Kick Starter/Drive
. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY __________________________________________________________________________________ SERVICE INFORMATION ..............7- 1 TROUBLESHOOTING ............... 7- 1 KICK STARTER.................. 7- 2 DRIVE BELT ..................7- 6 DRIVE PULLEY.................. 7- 8 STARTER PINION................
Page 83 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 SERVICE INFORMATION GENERAL INSTRUCTIONS • Avoid getting grease and oil on the drive belt and pulley faces. SPECIFICATIONS Standard (mm) Service Limit (mm) SH10DA SF10DA SH10DA SF10DA Item ～ 20.01 20.025 Drive pulley collar O.D. 19.97 ～...
Page 84: Kick Starter
. KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 Left Crankcase Cover 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.
Page 85 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 Kick Starter Spindle Remove the kick starter spindle and return 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.
Page 86 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 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.
Page 87 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 First install the washer and then the circlip onto the kick starter spindle. Install the kick lever. Washer Circlip Dowel Pins LEFT CRANKCASE COVER INSTALLATION First install the dowel pins and then the seal rubber.
Page 88 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 DRIVE BELT Remove the left crankcase cover. INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: SH10DA: 17mm replace if below SF10DA: 17mm replace if below ＊...
Page 89 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 Clutch/Driven Pulley Remove the drive belt from the clutch/ 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.
Page 90 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 Drive Pulley Face DRIVE PULLEY Starting Ratchet REMOVAL Hold the drive pulley with the holder and remove the 17mm drive face nut. Remove the starting ratchet, 17mm washer and drive pulley face. 17mm Drive Face Nut Movable Drive Face MOVABLE DRIVE FACE...
Page 91 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 Remove the weight rollers. Weight Roller MOVABLE DRIVE FACE INSPECTION Check each weight roller for wear or damage. Measure each roller O.D. Service Limit: SH10DA: 12.4mm replace if below SF10DA: 12.4mm replace if below Movable Drive Face DRIVE PULLEY INSTALLATION Install the drive pulley collar and movable...
Page 92 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 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.
Page 93 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 CLUTCH/DRIVEN PULLEY Clutch Outer 14mm Clutch Outer Nut 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.
Page 94 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 Remove the seal collar. Seal Collar Driven Pulley Oil Seal Pull out the guide roller pins from the driven pulley and then remove the O-rings and oil seal from the driven pulley. O-rings Guide Roller Pin CLUTCH/DRIVEN PULLEY...
Page 95 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below Measure the driven face spring free length. Service Limit: SH10DA: 82.6mm replace if below SF10DA: 82.6mm replace if below Check the driven face assembly for wear or damage.
Page 96 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 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.
Page 97 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 Bearing Driver Pilot Drive in a new needle bearing into the driven face with the mark facing up. Outer Driver Driven Pulley Oil Seal CLUTCH/DRIVEN PULLEY ASSEMBLY First install the movable driven face onto the driven face.
Page 98 . KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY SUPER 9 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.
Page 99 . FINAL REDUCTION SUPER 9 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SERVICE INFORMATION ..............8-1 TROUBLESHOOTING ............... 8-1 FINAL REDUCTION DISASSEMBLY ..........8-2 FINAL REDUCTION INSPECTION..........8-2 FINAL REDUCTION ASSEMBLY............ 8-5...
Page 100 . FINAL REDUCTION SUPER 9 SERVICE INFORMATION Specified Oil: SAE90# At disassembly: 0.12 liter At change: 0.1 liter SPECIAL TOOLS Bearing remover 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...
Page 101: Final Reduction
. FINAL REDUCTION SUPER 9 Bolts FINAL REDUCTION DISASSEMBLY Remove the rear wheel. ( 14-2) Remove the left crankcase cover. ( 7-2) Remove the clutch/driven pulley. ( 7-11) Drain the transmission gear oil into a clean container. Remove the transmission case cover attaching bolts.
Page 102 . FINAL REDUCTION SUPER 9 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 drive shaft and gear for wear or...
Page 103 . FINAL REDUCTION SUPER 9 Drive Shaft Bearing BEARING REPLACEMENT (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.
Page 104 . FINAL REDUCTION SUPER 9 Drive new bearings into the left crankcase. Install a new drive shaft oil seal. Bearing Outer Driver FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase. Drive Shaft Install the countershaft gear into the left crankcase.
Page 105 . FINAL REDUCTION SUPER 9 Dowel Pins Install the final gear and final shaft into the left crankcase. Install the dowel pins and a new gasket. Final Shaft Install the transmission case cover. Transmission Case Cover Install and tighten the transmission case cover bolts.
Page 106 . FINAL REDUCTION SUPER 9 After installation, fill the transmission case with the specified oil. ＊ • Place the motorcycle on its main stand on level ground. • 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.
Page 107: A.c. Generator
. A.C. GENERATOR SUPER 9 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ A.C. GENERATOR __________________________________________________________________________________ SERVICE INFORMATION ..............9-1 A.C. GENERATOR REMOVAL............9-2 A.C. GENERATOR INSTALLATION ..........9-5...
Page 108 . A.C. GENERATOR SUPER 9 SERVICE INFORMATION GENERAL INSTRUCTIONS • All A.C. generator maintenance and inspection can be made with the engine installed. • Refer to Section 15 for A.C. generator inspection. TORQUE VALUE Flywheel nut : 34.3～39.2N-m SPECIAL TOOLS Flywheel puller Universal holder...
Page 109 . A.C. GENERATOR SUPER 9 Bolts 〈SH10DA〉 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...
Page 110 . A.C. GENERATOR SUPER 9 Bolts 〈SF10DA〉 A.C. GENERATOR REMOVAL Remove the three bolts attaching the fan cover to remove the fan cover. Fan Cover Remove the cooling fan by removing the Bolt four bolts. Cooling Fan Hold the flywheel with an universal holder and then remove the flywheel nut.
Page 111 . A.C. GENERATOR SUPER 9 Remove the A.C. generator flywheel using Lock Nut Wrench 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 Stator Wire Clamp coil from the right crankcase.
Page 112 . A.C. GENERATOR SUPER 9 A.C. Generator Wire Connector A.C. 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. Woodruff Key Clean the taper hole in the flywheel off any burrs and dirt.
Page 113: Crankcase/Crankshaft
. CRANKCASE/CRANKSHAFT SUPER 9 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE/CRANKSHAFT __________________________________________________________________________________ SERVICE INFORMATION ..............10-1 TROUBLESHOOTING ............... 10-1 CRANKCASE SEPARATION ............10-2 CRANKSHAFT REMOVAL............... 10-2 CRANKSHAFT INSPECTION ............10-3 CRANKSHAFT INSTALLATION ............. 10-4 CRANKCASE ASSEMBLY..............10-6 10-0...
Page 114 . CRANKCASE/CRANKSHAFT SUPER 9 SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. • The following parts must be removed before separating the crankcase. Engine ( Section 5) Driven pulley ( Section 7) Carburetor ( Section 12) A.C.
Page 115 . CRANKCASE/CRANKSHAFT SUPER 9 CRANKCASE SEPARATION Remove the crankcase attaching bolts. Bolts Crankcase Puller Attach the crankcase puller on the right crankcase and remove the right crankcase from the left crankcase. Crankcase Puller CRANKSHAFT REMOVAL Attach the crankcase puller on the left crankcase and remove the crankshaft from the left crankcase.
Page 116 . CRANKCASE/CRANKSHAFT SUPER 9 Remove the remaining bearing on the crankshaft side using the universal 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.
Page 117 . CRANKCASE/CRANKSHAFT SUPER 9 Measure the crankshaft runout. Service Limit 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...
Page 118 Install the crankshaft into the left Crankcase Assembly Tool crankcase. ＊ • Apply KYMCO ULTRA motor oil or molybdenum disulfide to the crank- shaft bearings and connecting rod big end. • Apply grease to the lip of the oil seal and then install it.
Page 119 . CRANKCASE/CRANKSHAFT SUPER 9 Dowel Pins CRANKCASE ASSEMBLY Install the dowel pins and a new gasket to the crankcase mating surface. Assemble the crankcase halves. Crankcase Assembly Tool The distance between the right crankcase oil seal and crankcase surface is about 12.5±0.5 mm.
Page 120 . CRANKCASE/CRANKSHAFT SUPER 9 The distance between the left crankcase oil seal and crankcase surface is about 1.0mm. Oil Seal 1.0mm Install and tighten the crankcase attaching bolts. ＊ After assembly, check the crankshaft for smooth operation. 10-7...
Page 121: Cooling System
. COOLING SYSTEM SUPER 9 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 11- 1 TROUBLESHOOTING----------------------------------------------------- 11- 1 RADIATOR ------------------------------------------------------------------ 11- 3 WATER PUMP -------------------------------------------------------------- 11- 6 THERMOSENSOR---------------------------------------------------------- 11-12 THERMOSTAT-------------------------------------------------------------- 11-13 11-0...
Page 122 . COOLING SYSTEM SUPER 9 SERVICE INFORMATION GENERAL INSTRUCTIONS • The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame. • The engine must be cool before servicing the cooling system. When the coolant temperature is over 100℃, never remove the radiator cap to release the pressure because the boiling coolant may cause danger.
Page 123 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071 COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS) Freezing Point Mixing Rate KYMCO SIGMA Coolant Concentrate Distilled Water -9℃ -15℃ 360cc 825cc -25℃...
Page 124 . COOLING SYSTEM SUPER 9 RADIATOR Front Upper Cover RADIATOR INSPECTION Remove the front upper cover. ( 2-3) Remove the front lower cover. ( 2-3) Front Lower Cover Inspect the radiator soldered joints and Radiator seams for leaks. Blow dirt out from between core fins with compressed air.
Page 125 . COOLING SYSTEM SUPER 9 Upper Hose Loosen the hose band and disconnect the upper hose from the radiator. Radiator Loosen the hose band and disconnect the lower hose from the radiator. Lower Hose Remove the two bolts and the radiator. Radiator Bolts 11-4...
Page 126 . COOLING SYSTEM SUPER 9 RADIATOR BRACKET REMOVAL/ Nuts INSTALLATION Remove the two nuts to remove the radiator bracket. The installation sequence is the reverse of removal. Radiator Bracket RADIATOR INSTALLATION Radiator Install the radiator on the radiator bracket with the two bolts. Bolts Connect the upper and lower hoses and Upper Hoses...
Page 127: Water Pump
. COOLING SYSTEM SUPER 9 Upper Hose Reinstall the upper and lower hoses, make sure the bands are secured. Reserve Tank Lower Hose Reserve Tank Fill the reserve tank with coolant. ( 3-10) Air Duct Check for coolant leaks. Install the front upper and lower cover. Water Pump WATER PUMP MECHANICAL SEAL (WATER SEAL)
Page 128 . COOLING SYSTEM SUPER 9 WATER PUMP/IMPELLER REMOVAL Remove the engine from the frame. ( 5-2) Remove the three bolts and the water pump Bolts cover, gasket and two dowel pins. Water Pump Cover Remove the water pump impeller. Impeller ＊...
Page 129 . COOLING SYSTEM SUPER 9 Inspect the mechanical (water) seal and seal Seal Washer (Porcelain) Mechanical Seal washer for wear or damage. ＊ The mechanical seal and seal washer must be replace as a set. Impeller WATER PUMP SHAFT REMOVAL Bolts Bolts Disconnect the water hose from the right...
Page 130 . COOLING SYSTEM SUPER 9 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) Outer Bearing Remove the water pump shaft outer bearing.
Page 131 . COOLING SYSTEM SUPER 9 Water Pump Assembly WATER PUMP BEARING/ 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.
Page 132 . COOLING SYSTEM SUPER 9 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.
Page 133 . COOLING SYSTEM SUPER 9 Thermosensor THERMOSENSOR THERMOSENSOR REMOVAL Remove the seat, met-in box and frame body cover. Drain the coolant. Disconnect the thermosensor wire. Remove the thermosensor. Thermosensor Wire THERMOSENSOR INSPECTION Thermosensor Suspend the thermosensor in a pan of water over a burner and measure the resistance through the sensor as the water heats up.
Page 134 . COOLING SYSTEM SUPER 9 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 Remove the two screws and separate the thermostat housing cover .
Page 135 . COOLING SYSTEM SUPER 9 THERMOSTAT INSTALLATION The installation sequence is the reverse of removal. Fill the cooling system with the specified coolant. ( 3-10) Thermostat Housing 11-14...
Page 136: Carburetor
. CARBURETOR SUPER 9 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CARBURETOR __________________________________________________________________________________ SERVICE INFORMATION ..............12- 1 TROUBLESHOOTING ............... 12- 1 THROTTLE VALVE DISASSEMBLY ..........12- 2 THROTTLE VALVE INSTALLATION..........12- 3 CARBURETOR REMOVAL .............. 12- 4 AUTO BYSTARTER................12- 5 FLOAT CHAMBER ................
Page 137 . CARBURETOR SUPER 9 SERVICE INFORMATION GENERAL INSTRUCTIONS • 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. • All cables, fuel lines and wires must be routed and secured at correct locations. •...
Page 138 . CARBURETOR SUPER 9 THROTTLE VALVE DIS- ASSEMBLY Remove the rear carrier. ( 2-3) Remove the met-in box. ( 2-4) Loosen the carburetor cap and remove the throttle valve. Carburetor Cap Throttle Valve Disconnect the throttle cable from the throttle valve. Carburetor Cap Rubber Seal Remove the throttle valve spring,...
Page 139 . CARBURETOR SUPER 9 Throttle Valve Remove the jet needle by removing the needle clip. Check the jet needle and throttle valve for wear or damage. Needle Clip Jet Needle Spring Rubber Seal Carburetor Cap THROTTLE VALVE INSTALLA- TION Install the jet needle on the throttle valve and secure with the needle clip.
Page 140: Carburetor Removal
. CARBURETOR SUPER 9 Groove Install the throttle valve by aligning the groove in the throttle valve with the throttle stop screw. Throttle Stop Screw Carburetor Cap Tighten the carburetor cap. After installation, perform the following adjustments and inspections. • Throttle cable free play ( 3-12) •...
Page 141: Auto Bystarter
. CARBURETOR SUPER 9 Remove the two carburetor lock nuts. Remove the carburetor and water hose. Water Hose AUTO BYSTARTER AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals. Resistance: 5Ω (10 minutes minimum after stopping the engine) If the resistance exceeds 5Ω, replace the auto bystarter with a new one.
Page 142 . CARBURETOR SUPER 9 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.
Page 143: Float Chamber
. CARBURETOR SUPER 9 Auto Bystarter AUTO BYSTARTER INSTALLATION Install the auto bystarter into the carburetor body until it bottoms.. Install the set plate and then tighten the two screws. Screws Set Plate FLOAT CHAMBER Screws Remove the two float chamber screws and the float chamber.
Page 144 . CARBURETOR SUPER 9 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 Main Jet Before removing the throttle stop screw or air screw, record the number of rotations until it seats lightly.
Page 145: Float Level Inspection
. CARBURETOR SUPER 9 Needle Jet holder Main Jet FLOAT CHAMBER ASSEMBLY 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.
Page 146 . CARBURETOR SUPER 9 O-rings CARBURETOR INSTALLATION ＊ 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.
Page 147 . CARBURETOR SUPER 9 Bolts REED VALVE 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 Reed Stopper Reeds INSPECTION Check the reed valve for damaged or weak reeds.
Page 148: Steering Handlebar/Front Wheel/Front Brake/Front
. STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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...
Page 149 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SERVICE INFORMATION GENERAL INSTRUCTIONS • Remove 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.
Page 150 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling • Excessively tightened steering stem top • Bent rim • Loose front axle cone race • Broken steering balls • Bent spoke plate •...
Page 151 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Master Cylinders STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers. ( 2-7) Remove the front and rear brake master cylinder attaching bolts. Remove the front upper cover. ( 2-3) Remove the front lower cover.
Page 152 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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 Throttle Grip Throttle Cable Lubricate the throttle grip front end with grease and then install the throttle grip.
Page 153 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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. Speedometer Gear Unit Axle Nut INSPECTION...
Page 154 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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.
Page 155 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Pack all bearing cavities with grease. Driver Handle Drive in the left bearing. Install the distance collar. Drive in the right bearing. ＊ • Do not allow the bearings to tilt while driving them in.
Page 156: Front Brake
. STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Holder FRONT BRAKE Bolts BRAKE MASTER CYLINDER REMOVAL Remove the handlebar covers. ( 2-7) First drain the brake fluid from the hydraulic brake system. Disconnect the front stop switch wire connector.
Page 157 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSPECTION Measure the brake master cylinder I.D. 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 lst and 2nd rubber cups for wear.
Page 158 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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.
Page 159 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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 or water to enter the brake system during refilling.
Page 160 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Remove the piston from the brake caliper. If necessary, use compressed air to squeeze 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.
Page 161 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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.
Page 162: Front Shock Absorber
. STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Fluid Tube Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt. Torque: 24.5～34.3N-m Fill the brake reservoir with the specified brake fluid and bleed air from the brake system.
Page 163 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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 a container under the front shock absorber to drain the engine oil from it.
Page 164 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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.
Page 165 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Circlip Dust Boot Install the oil seal 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.
Page 166 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK FRONT FORK REMOVAL Remove the handlebar covers. ( 2-6) Remove the steering handlebar. ( 13-4) Remove the front upper cover. ( 2-5) Remove the front lower cover. ( 2-5) Remove the front inner fender. ( 2-6) Remove the front wheel.
Page 167 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK BALL RACE REPLACEMENT Ball Race Remover Drive out the ball races. Drive in new ball races. ＊ Outer Driver Be sure to drive the ball races into place completely. Top Cone Race INSTALLATION Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race...
Page 168 . STEERING HANDLEBAR/FRONT WHEEL/FRONT SUPER 9 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Apply grease to the top cone race and install Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely. ＊...
Page 169 . REAR BRAKE/REAR FORK/REAR SUPER 9 WHEEL/REAR SHOCK ABSORBER __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REAR BRAKE/REAR FORK/REAR WHEEL/ REAR SHOCK ABSORBER __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 14-1 TROUBLESHOOTING----------------------------------------------------- 14-1 REAR BRAKE --------------------------------------------------------------- 14-2 REAR FORK ----------------------------------------------------------------- 14-3 REAR WHEEL--------------------------------------------------------------- 14-3 REAR BRAKE DRUM ----------------------------------------------------- 14-5 REAR SHOCK ABSORBER ---------------------------------------------- 14-7 14-0...
Page 170 . REAR BRAKE/REAR FORK/REAR SUPER 9 WHEEL/REAR SHOCK ABSORBER SERVICE INFORMATION GENERAL INSTRUCTIONS • When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid scalding. • During servicing, keep oil or grease off the brake pads and brake disk. SPECIFICATIONS Item Standard (mm)
Page 171 . REAR BRAKE/REAR FORK/REAR SUPER 9 WHEEL/REAR SHOCK ABSORBER Brake Caliper Fluid Tube Bolt REAR BRAKE (SH10DA) 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.
Page 172 . REAR BRAKE/REAR FORK/REAR SUPER 9 WHEEL/REAR SHOCK ABSORBER REAR FORK (SF10DA) REMOVAL Remove the exhaust muffler. ( 2-6) Remove the rear brake caliper. ( 14-2) Remove the rear axle nut and remove the collar. Remove the rear fork. The installation sequence is the reverse of removal.
Page 173 . REAR BRAKE/REAR FORK/REAR SUPER 9 WHEEL/REAR SHOCK ABSORBER 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 removal. Torque: Rear axle nut: 78.4～98.0N-m Axle Nut Brake Caliper Bolts INSTALLATION...
Page 174 . REAR BRAKE/REAR FORK/REAR SUPER 9 WHEEL/REAR SHOCK ABSORBER REAR BRAKE DRUM Remove the rear wheel. ( 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 ＊...
Page 175 . REAR BRAKE/REAR FORK/REAR SUPER 9 WHEEL/REAR SHOCK ABSORBER Brake Arm Bolt Remove the brake arm bolt to remove the Wear Indicator Plate brake arm, wear indicator plate and felt seal. Remove the brake cam. Brake Arm Brake Cam REAR BRAKE ASSEMBLY Apply grease to the anchor pin and brake shoe moving parts.
Page 176 . REAR BRAKE/REAR FORK/REAR SUPER 9 WHEEL/REAR SHOCK ABSORBER 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) Brake Arm Pin Adjusting Nut Air Cleaner...
Page 177 . REAR BRAKE/REAR FORK/REAR SUPER 9 WHEEL/REAR SHOCK ABSORBER 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.
Page 178 . REAR BRAKE/REAR FORK/REAR SUPER 9 WHEEL/REAR SHOCK ABSORBER 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...
Page 179 . ELECTRICAL EQUIPMENT SUPER 9 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ELECTRICAL EQUIPMENT __________________________________________________________________________________ SERVICE INFORMATION ..............15- 1 TROUBLESHOOTING ............... 15- 1 CHARGING SYSTEM ................ 15- 3 BATTERY.................... 15- 4 IGNITION SYSTEM ................15- 7 STARTING SYSTEM................15-11 15-0...
Page 180 . ELECTRICAL EQUIPMENT SUPER 9 SERVICE INFORMATION GENERAL INSTRUCTIONS • It is not necessary to check the battery electrolyte or fill with distilled water. • Remove the battery from the motorcycle for charging. Do not remove the electrolyte cap.. • Do not quick charge the battery. Quick charging should only be done in an emergency.. •...
Page 181 . ELECTRICAL EQUIPMENT SUPER 9 IGNITION SYSTEM No spark at plug Engine starts but turns poorly • Faulty spark plug • Ignition primary circuit • Poorly connected, broken or shorted wire —Faulty ignition coil —Between A.C. generator and CDI unit —Poorly connected wire or connector •...
Page 182 . ELECTRICAL EQUIPMENT SUPER 9 CHARGING SYSTEM 5.9Ω 15-3...
Page 183 . ELECTRICAL EQUIPMENT SUPER 9 Front Tool Box BATTERY BATTERY REMOVAL Open the front tool box and remove the bolt. Remove the front tool box. ( 2-4) Disconnect the battery cables. ＊ First disconnect the battery negative (-) cable and then the positive (+) cable. Remove the bolt and battery bracket.
Page 184 . ELECTRICAL EQUIPMENT SUPER 9 PERFORMANCE TEST Warm up the engine. Remove the floor mat and battery cover. ＊ 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.
Page 185 . ELECTRICAL EQUIPMENT SUPER 9 RESISTOR INSPECTION Remove the front upper/lower cover. ( 2-3) 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: 9.9～10.5Ω Resistor B: 5.6～6.2Ω...
Page 186 . ELECTRICAL EQUIPMENT SUPER 9 IGNITION SYSTEM 15-7...
Page 187 . ELECTRICAL EQUIPMENT SUPER 9 IGNITION COIL INSPECTION Continuity Test ＊ This test is to inspect the continuity of ignition coil. Remove the met-in box. ( 12-4) Measure the resistance between the ignition coil primary coil terminals. Resistance (20℃): 0.153～0.187Ω Measure the secondary coil resistance between the spark plug cap and the primary coil terminal as Figure A shown.
Page 188 . ELECTRICAL EQUIPMENT SUPER 9 Performance Test Remove the ignition coil. Ignition Coil Inspect the ignition coil with an ignition coil tester. Ignition Coil Tester AC 110V ＊ 07508-0070100 6V/12V Follow the ignition coil tester manufac- Watch Window Changeover turer‘s instructions. Switch Black(-) Black...
Page 189 . ELECTRICAL EQUIPMENT SUPER 9 Coupler CDI UNIT INSPECTION Open the front tool box and remove the 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 Green Black/ Yellow...
Page 190 . ELECTRICAL EQUIPMENT SUPER 9 STARTING SYSTEM 15-11...
Page 191: Starter Relay Inspection
. ELECTRICAL EQUIPMENT SUPER 9 Starter Relay 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 Yellow/Red terminal to the 12V battery positive (+) terminal and the relay yellow/red terminal to...
Page 192 . ELECTRICAL EQUIPMENT SUPER 9 Battery (+) Terminal Starter Motor STARTER MOTOR INSPECTION Connect a battery across the starter motor and check for its operation. ＊ 1. Do not turn the starter motor for a long time. 2. This inspection should be done with a fully charged battery.
Page 193: Instrument/Switches/Lights
. INSTRUMENT/SWITCHES/LIGHTS SUPER 9 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSTRUMENT/SWITCHES/LIGHTS __________________________________________________________________________________ SERVICE INFORMATION ..............16-1 TROUBLESHOOTING ............... 16-1 FUEL UNIT..................16-2 OIL METER ..................16-3 SWITCHES ..................16-4 STOP SWITCH INSPECTION/HORN ..........16-6 BULB REPLACEMENT ..............16-7 INSTRUMENT/HEADLIGHT ............16-8 16-0...
Page 194 . INSTRUMENT/SWITCHES/LIGHTS SUPER 9 SERVICE INFORMATION GENERAL INSTRUCTIONS • Wires should be connected to other wires of the same color. Couplers must be connected to other couplers of the same color. • All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting.
Page 195 . INSTRUMENT/SWITCHES/LIGHTS SUPER 9 Fuel Unit FUEL UNIT ＊ No Smoking! REMOVAL Remove the frame body cover. ( 2-3) 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.
Page 196 . INSTRUMENT/SWITCHES/LIGHTS SUPER 9 INSTALLATION The installation sequence is the reverse of removal. ＊ • Align the tab on the fuel unit with the groove on the fuel tank. • Turn the retainer clockwise to secure it. Groove OIL METER Oil Meter Float INSPECTION...
Page 197 . INSTRUMENT/SWITCHES/LIGHTS SUPER 9 Move the oil meter float up and down to see Oil Indicator Light if the oil indicator light will go out and come ＊ If the oil indicator light does not light, check for burned bulb, loose wire or connector.
Page 198 . INSTRUMENT/SWITCHES/LIGHTS SUPER 9 HEADLIGHT SWITCH INSPECTION Remove the handlebar lower cover. ( 2-7) Disconnect the headlight switch wire coupler and check for continuity between wire terminals. Color Blue/White Yellow Brown Pink Symbol ○ ○ ○ ○ ○ ○ ○ Headlight Switch DIMMER SWITCH INSPECTION Check for continuity between wire terminals.
Page 199 . INSTRUMENT/SWITCHES/LIGHTS SUPER 9 STARTER SWITCH INSPECTION Check for continuity between wire terminals. Push the starter button when measuring. Color Yellow/Red Green Symbol FREE ○ ○ PUSH Starter Switch HORN SWITCH INSPECTION Check for continuity between wire terminals. Push the horn button when measuring. Color Light Green Black...
Page 200 . INSTRUMENT/SWITCHES/LIGHTS SUPER 9 Battery Horn Terminal HORN INSPECTION Remove the front upper/lower cover. ( 2-3) 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.
Page 201 . INSTRUMENT/SWITCHES/LIGHTS SUPER 9 INSTRUMENT Instrument Bulbs Replacement Remove three screws attaching the instrument bulbs. Remove the instrument bulbs cover. Remove the bulbs and replace with new ones. Bulb Sockets Screws SPEEDOMETER REMOVAL Disconnect the speedometer cable. Disconnect the speedometer wire connector. Remove the two screws attaching the speedometer.
Page 202: Evaporative/Exhaust Emission
. EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM SUPER 9 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM __________________________________________________________________________________ EXHAUST EMISSION CONTROL SYSTEM........17-1 EXHAUST MUFFLER ................ 17-2 EXHAUST EMISSION RELATED SYSTEM INSPECTION ... 17-3 17-0...
Page 203 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM SUPER 9 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.
Page 204 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM SUPER 9 Exhaust Muffler Joint Lock Nut EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts and two exhaust muffler lock bolts. Remove the exhaust muffler. ＊ • The temperature of exhaust muffler is very high.
Page 205 . EVAPORATIVE/EXHAUST EMISSION CONTROL SYSTEM SUPER 9 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 1.

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