KYMCO Bet & Win 125 User Manual Download Page 62

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5. ENGINE REMOVAL/INSTALLATION

5-5

Bet & Win 125/150

ENGINE INSTALLATION

Install the engine in the reverse order of

removal.

Tighten the engine mounting bolts.

Torque

: 49N-m

Tighten the rear shock absorber upper mount

bolts.

Torque

: 39.2N-m

After installation, inspect and adjust the

following:

•

Throttle grip free play (

3-3)

•

Fill the rear brake reservoir with brake fluid

and bleed air from the rear brake.

•

Fill the cooling system with coolant and

start the engine to bleed air from the

system.

Engine Mounting Bolt

Engine Hanger Bolt

Rear Shock Absorber Upper Mount Bolts

Summary of Contents for Bet & Win 125

Page 1: ...art with an assembly or system illustration and troubleshooting for the section The subsequent pages give detailed procedures for the section KWANG YANG MOTOR CO LTD OVERSEAS SALES DEPARTMENT OVERSEAS...

Page 2: ..._________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMAT...

Page 3: ...1 GENERAL INFORMATION 1 1 Bet Win 125 150 SERIAL NUMBER Location of Engine Serial Number Location of Frame Serial Number Vehicle Identification Serial Number...

Page 4: ...Valve Intake 0 1 clearance cold Exhaust 0 1 Idle speed rpm 1500rpm Lubrication type Forced pressure wet sump Oil pump type Inner outer rotor type Oil filter type Full flow filtration Oil capacity 1 1...

Page 5: ...0 Valve Intake 0 1 clearance cold Exhaust 0 1 Idle speed rpm 1500rpm Lubrication type Forced pressure wet sump Oil pump type Inner outer rotor type Oil filter type Full flow filtration Oil capacity 1...

Page 6: ...gine oil before reassembly n Apply or add designated greases and lubricants to the specified lubrication points n After reassembly check all parts for proper tightening and operation n When two person...

Page 7: ...rotruding or loose n The connector shall be inserted completely n If the double connector has a lock lock it at the correct position n Check if there is any loose wire n Before connecting a terminal c...

Page 8: ...s n Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws n Route harnesses so they are neither pulled tight nor have excessive slack n Protect...

Page 9: ...s thoroughly and operate according to the operating instructions n Be careful not to drop any parts n When rust is found on a terminal remove the rust with sand paper or equivalent before connecting n...

Page 10: ...p nut Valve adjusting lock nut Cam chain tensioner slipper bolt Oil bolt Clutch outer nut Clutch drive plate nut Flywheel nut Oil pump bolt Cylinder head cover bolt Spark plug Cam chain tensioner bolt...

Page 11: ...E014 Water pump mechanical seal removal installation Kick starter spring remover Kick starter spring removal Gear remover Starter gear removal Valve adjuster E012 Tapper adjustment Float level gauge...

Page 12: ...onnecting rod big end Crankshaft Cranksahft one way clutch movable part Oil pump drive chain Starter reduction gear engaging part Countershaft gear engaging part Final gear engaging part Bearing movab...

Page 13: ...for parts not listed 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 Seat Lock Rear Wheel Bearing Gr...

Page 14: ...1 12 Bet Win 125 150 CABLE HARNESS ROUTING Front Stop Switch Rear Stop Switch Throttle Cable Radiator Front Brake Fluid Tube Rear Brake Fluid Tube Speedometer Cable Horn Pressure Type Radiator Cap Ra...

Page 15: ...AL INFORMATION 1 13 Bet Win 125 150 Front Brake Fluid Tube Fuel Pump Fuel Tank Inlet Tube Water Hose Ignition Switch Fuel Filler Water Hoses Thermostatic Switch Fuel Tank Breather Tube Radiator Air Ve...

Page 16: ...Win 125 150 Throttle Cable Speedometer Cable Reserve Tank Cap Radiator Air Vent Tube Rear Brake Fluid Tube Fuel Tank Inlet Tube Water Hose Fuel Filler Fuel Tank Breather Tube Throttle Cable Front Stop...

Page 17: ...Win 125 150 Starter Relay Fuel Tube Battery Cable Battery Cable Ignition Coil Auto Bystarter Wire Thermostat Carburetor Air Cut off Valve A C V Regulator Rectifier Charging Indicator Fuse Box Starter...

Page 18: ...el Tube Auto Bystarter Spark Plug Cap Starter Motor Fuel Pump Fuel Unit Wire Wire Harness Spark Plug Cap Throttle Cable Vacuum Vacuum Fuel Pump Vacuum Tube Ground Wire Oil Vapor Recovery Tube Fuel Pum...

Page 19: ...1 GENERAL INFORMATION 1 17 Bet Win 125 150 WIRING DIAGRAM...

Page 20: ...ston rings Blown cylinder head gasket Flaws in cylinder head Seized valve Improper valve timing Faulty auto bystarter Air leaking through intake pipe Incorrect ignition timing Incorrectly adjusted pil...

Page 21: ...ng too early Air in cooling system Excessive carbon build up in combustion chamber Poor quality fuel Clutch slipping Mixture too lean Ignition timing too early Start engine and accelerate lightly for...

Page 22: ...Faulty ignition coil Broken or shorted high tension wire Faulty ignition switch Damaged air cut off valve diaphragm Damaged air cut off valve spring Remove spark plug and install it into spark plug ca...

Page 23: ...e Clean and unclog Cam timing gear aligning marks not aligned Faulty spring Inspection Adjustment Symptom Probable Cause Check ignition timing Check carburetor jets for clogging Check fuel pump for fu...

Page 24: ...d Excessive carbon build up in combustion chamber Damaged cam chain tensioner Worn cam gear teeth Worn or damaged cam chain Extended cam chain Faulty crankshaft bearing Worn crank pin bearing Worn or...

Page 25: ...arings Weak driven face spring Worn or seized driven pulley bearings Worn or slipping drive belt Worn weight rollers Worn or seized driven pulley bearings Oil or grease fouled drive belt Worn drive be...

Page 26: ...ter pinion Starter relay shorted or stuck Inspection Adjustment Inspection Adjustment Inspection Adjustment Symptom Symptom Symptom Check operation of stop switch by applying brake Stoplight does not...

Page 27: ...Faulty ignition coil Replace with a new spark plug and inspect again Check CDI unit coupler for looseness Inspection Adjustment Symptom Probable Cause Normal Abnormal Normal Abnormal Normal Abnormal...

Page 28: ...lator rectifier Broken or poorly connected regulator rectifier black wire Limit voltage too high Start engine and test limit voltage of battery terminals Measure battery limit voltage with an electric...

Page 29: ...om Remove fuel unit and check operation of pointer by moving float up and down Remove fuel unit and check operation of pointer by moving float up and down Signals operate properly Signals dim remain o...

Page 30: ...ing stem nut POOR BRAKE PERFORMANCE Worn brake linings Foreign matter on brake linings Rough brake drum contacting area Worn brake linings Foreign matter on brake linings Rough brake drum contacting a...

Page 31: ...___________________________________________________ __________________________________________________________________________________ _________________________________________________________________...

Page 32: ...2 EXHAUST MUFFLER FRAME COVERS 2 1 Bet Win 125 150 SCHEMATIC DRAWING...

Page 33: ...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 Exhaust muffler joint lock nut 11 8N m TROUBLE...

Page 34: ...t lock hex bolts Remove the four hex bolts Remove the rear carrier and hand rail FRAME BODY COVER REMOVAL Remove the one screws on the bottom of the center cover Remove the center cover Remove the two...

Page 35: ...e five screws and four screws attaching the front right and left side covers Remove the two bottom cover adjusting screws Remove the front right and left side covers Remove the air box four screws Rem...

Page 36: ...the front lower cover Remove the four screws on the back of the front lower cover Disconnect the right left turn signal light wire connectors Remove the front lower cover The installation sequence is...

Page 37: ...ve the two bolts attaching the fender Remove the front fender cover The installation sequence is the reverse of removal EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts Remove th...

Page 38: ..._________________________________________________________ INSPECTION ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION 3 1 MAINTENANCE S...

Page 39: ...SPECIFICATIONS ENGINE Throttle grip free play 2_ 6mm Spark plug NGK DPR7EA9 Spark plug gap 0 9mm Valve clearance IN 0 1mm EX 0 1mm Idle speed 1600rpm Engine oil capacity Cylinder compression 15 2kg c...

Page 40: ...te 2 3 I R R Spark plug Clean at every 3000km and replace if necessary Brake system I I I I I I Drive belt I Suspension I I Nut bolt fastener I Tire I I Steeringhead bearing I I I Brake fluid Perform...

Page 41: ...movement Measure the throttle grip free play Free Play 2_ 6mm Major adjustment of the throttle grip free play is made with the adjusting nut at the carburetor side Adjust by loosening the lock nut and...

Page 42: ...mmended oil through the oil filler hole Oil Capacity At disassembly 1 1 liter At change 0 9 liter RecommendedOil SAE 15W40 API SG CD Start the engine and check for oil leaks Stop the engine and rechec...

Page 43: ...plug Check the spark plug for wear and fouling deposits Clean any fouling deposits with a spark plug cleaner or a wire brush Specified Spark Plug NGK DP7EA9 Measure the spark plug gap Spark Plug Gap 0...

Page 44: ...ETOR IDLE SPEED Lift up the seat and remove the inspection cover Warm up the engine before this operation Start the engine and connect a tachometer Turn the throttle stop screw to obtain the specified...

Page 45: ...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 com...

Page 46: ...m Fill the final reduction with the recommended oil SAE90 Gear Oil Capacity At disassembly 200cc At change 180cc Reinstall the oil check bolt and check for oil leaks DRIVE BELT Remove the left crankca...

Page 47: ...the upper and lower level lines If necessary fill the reserve tank with recommended coolant to the F level line Recommended Coolant SIGMA Coolant Standard Concentration 30 COOLANT REPLACEMENT Remove...

Page 48: ...ree plays BRAKE FLUID 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...

Page 49: ...e 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 a...

Page 50: ..._ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM _____________...

Page 51: ...4 LUBRICATION SYSTEM 4 1 Bet Win 125 150 LUBRICATION SYSTEM Oil Pump Oil Filter Screen Crankshaft Rocker Arm Shaft...

Page 52: ...ump is installed check each part for oil leaks SPECIFICATIONS OIL PUMP Standard mm Service Limit mm Inner rotor to outer rotor clearance 0 15 0 20 Outer rotor to pump body clearance 0 15_ 0 20 0 25 Ro...

Page 53: ...cap Remove the oil filter screen and spring Check the oil filter screen for clogging or damage and replace if necessary Check the filter screen O ring for damage and replace if necessary Install the o...

Page 54: ...r 10 3 Remove the A C generator starter driven gear 10 4 Remove the attaching bolt and oil separator cover Pry the circlip off and remove the oil pump driven gear then remove the oil pump drive chain...

Page 55: ...ure the inner rotor to outer rotor clearance Service Limit 0 20mm replace if over Measure the rotor end to pump body clearance Service Limit 0 12mm replace if over OIL PUMP ASSEMBLY Install the outer...

Page 56: ...ng OIL PUMP INSTALLATION Install the oil pump and oil separator and tighten the two bolts Make sure that the pump shaft rotates freely The arrow of oil pump is upside Install the pump drive chain and...

Page 57: ...__________________________________________________________________ __________________________________________________________________________________ __________________________________________________...

Page 58: ...5 ENGINE REMOVAL INSTALLATION 5 1 Bet Win 125 150 SCHEMATIC DRAWING...

Page 59: ...oving the engine After the engine is installed fill the cooling system with coolant and be sure to bleed air from the water jacket Start the engine to check for coolant leaks Before removing the engin...

Page 60: ...he water hose Disconnect the starter motor wire that goes to the starter relay Disconnect the fuel tube and vacuum tube that go to the carburetor from the fuel pump Disconnect the vacuum tube from the...

Page 61: ...g bolts and pull out the engine with the engine hanger backward ENGINE HANGER REMOVAL Remove the engine hanger bolts to remove the engine hanger Inspect the engine hanger bushings and stopper rubber f...

Page 62: ...rear shock absorber upper mount bolts Torque 39 2N m After installation inspect and adjust the following Throttle grip free play 3 3 Fill the rear brake reservoir with brake fluid and bleed air from...

Page 63: ...____________________________________________ __________________________________________________________________________________ CYLINDER HEAD VALVES ___________________________________________________...

Page 64: ...6 CYLINDER HEAD VALVES 6 1 Bet Win 125 150 SCHEMATIC DRAWING...

Page 65: ...head warpage 0 05 0 05 IN 30 8763 30 8763 30 75 30 75 EX 30 4081 30 4081 30 26 30 26 IN 10 00_ 10 018 10 00_ 10 018 10 10 10 10 EX 10 00_ 10 018 10 00_ 10 018 10 10 10 10 Valve rocker arm shaft IN 9 9...

Page 66: ...ve stem oil seal Compression too low Incorrect valve clearance adjustment Abnormal noise Burned or bend valves Incorrect valve clearance adjustment Incorrect valve timing Sticking valve or broken valv...

Page 67: ...crankcase Hold the round hole on the camshaft gear facing up and the location is the top dead center on the compression stroke Remove the two bolts attaching cam chain tensioner and the tensioner Firs...

Page 68: ...s SH30CA IN 30 75mm replace if below SH25CA EX 30 26mm replace if below Check each camshaft bearing for play or damage Replace the camshaft assembly with a new one if the bearings are noisy or have ex...

Page 69: ...diator and water jacket then remove the thermostat water hose Remove the camshaft 6 4 Remove the carburetor and intake manifold Remove the bolt attaching the thermostat housing and the thermostat hous...

Page 70: ...using a valve spring compressor Remove carbon deposits from the exhaust port and combustion chamber Valve Spring Compressor Cylinder Head Be sure to compress the valve springs with a valve spring comp...

Page 71: ...s Inner IN EX 29 3mm replace if below Outer IN EX 32 0mm replace if below VALVE VALVE GUIDE Inspect each valve for bending burning scratches or abnormal stem wear Check valve movement in the guide Mea...

Page 72: ...install the intake and exhaust valve rocker arms then installtherocker arm shafts Gasket Cam Chain Guide Valve Rocker Arms Plastic Hammer Cam Chain Cylinder Head Camshaft Holder Be careful not to dama...

Page 73: ...the camshaft gear Install the dowel pins Install the camshaft holder washers and nuts on the cylinder head Tighten the four cylinder head nuts and the two bolts between the cylinder head and cylinder...

Page 74: ...and tighten the sealing bolt Torque 2 9_ 5 8N m CYLINDER HEAD COVER INSTALLATION Adjust the valve clearance 3 6 Install a new cylinder head cover O ring and install the cylinder head cover Install and...

Page 75: ...________________________________ __________________________________________________________________________________ __________________________________________________________________________________ C...

Page 76: ...7 CYLINDER PISTON 7 1 Bet Win 125 150 SCHEMATIC DRAWING...

Page 77: ...O D measuring position 9mm from bottom of skirt 9mm from bottom of skirt 9mm from bottomof skirt 9mm from bottomof skirt Piston to cylinder clearance 0 010_ 0 04 0 0 010_ 0 04 0 0 01 0 01 Piston pin...

Page 78: ...nder Remove the cylinder gasket and dowel pins Clean any gasket material from the cylinder surface PISTON REMOVAL Remove the piston pin clip Press the piston pin out of the piston Cylinder Base Bolt W...

Page 79: ...o groove clearance Service Limits Top 0 09mm replace if over 2nd 0 09mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom Measure the piston ring end gap Ser...

Page 80: ...iston pin in both X and Y directions Service Limit 58 10mm repair or replace if below SH30CA 57 50mmrepair or replace if over SH25CA 52 50mmrepair or replace if over Measure the cylinder to piston cle...

Page 81: ...over PISTON RING INSTALLATION Install the piston rings onto the piston Apply engine oil to each piston ring Second Side Rail Top Be careful not to damage the piston and piston rings during assembly Al...

Page 82: ...with clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings Gasket Cylinder Dowel Pin Be careful not to drop foreign matters into the crankcase Position the pist...

Page 83: ...he cylinder base bolt Install the cam chain guide Connect the water hose to the cylinder Install the cylinder head 6 9 Tighten the cylinder base bolt Insert the tab on the cam chain guide into the cyl...

Page 84: ...___________________________________ __________________________________________________________________________________ _________________________________________________________________________________...

Page 85: ...8 DRIVE AND DRIVEN PULLEYS KICK STARTER 8 1 Bet Win 125 150 SCHEMATIC DRAWING...

Page 86: ...3_ 4 037 2 0 Clutch outer I D 130 0_ 130 2 130 5 Driven face spring free length 88 3 83 2 Driven face O D 33 965_ 33 985 33 94 Movable driven face I D 34 00_ 34 025 34 06 Weight roller O D 16 99_ 17 0...

Page 87: ...dowel pins INSTALLATION Install the dowel pins and the seal rubber Install the left crankcase cover Install the cable clamp to the specified location Install and tighten the left crankcase cover bolt...

Page 88: ...r and remove the drive face nut and washer Remove the drive pulley face Universal Holder Remove the drive belt from the movable drive face INSPECTION Check the drive belt for cracks separation or abno...

Page 89: ...mbly Remove the drive pulley collar DISASSEMBLY Remove the ramp plate Remove the weight rollers INSPECTION Check each weight roller for wear or damage Measure each weight roller O D Service Limit 16 0...

Page 90: ...ce bushing assemblyy I D Service Limit 27 20mm replace if over Check the drive pulley collar for wear or damage Measure the O D of the drive pulley collar sliding surface Service Limit 26 90mm replace...

Page 91: ...e pulley collar into the movable drive face INSTALLATION Install the movable drive face onto the crankshaft Lay the drive belt on the driven pulley Set the drive belt on the drive pulley collar Drive...

Page 92: ...e cover 8 3 Remove the drive pulley and drive belt 8 4 Hold the clutch outer with the universal holder and remove the clutch outer nut Universal Holder Remove the clutch outer INSPECTION Inspect the c...

Page 93: ...tch driven pulley assembly with the clutch spring compressor Clutch Spring Compressor Set the tool in a vise and remove the clutch drive plate nut Lock Nut Wrench 39mm Loosen the clutch spring compres...

Page 94: ...om the driven face Remove the oil seal from the movable driven face INSPECTION Measure the driven face spring free length Service Limit 83 2mm replace if below Check the driven face assembly for wear...

Page 95: ...le bearing out of the driven pulley face Remove the snap ring and drive the outer bearing out of the driven face Apply grease to the outer bearing Drive a new outer bearing into the driven face with t...

Page 96: ...Bet Win 125 150 Press a new needle bearing into the driven face Bearing Driver CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch Circlips Retainer Plate Special Keep...

Page 97: ...nstall the clutch weights shoes and clutch springs onto the drive plate Install the retainer plate and secure with the circlips CLUTCH DRIVEN PULLEY ASSEMBLY Clean the pulley faces and remove any grea...

Page 98: ...all the drive plate nut Set the tool in a vise and tighten the drive plate nut to the specified torque Torque 49 0_ 58 8N m Clutch Spring Compressor Outer Driver 32x35mm INSTALLATION Install the clutc...

Page 99: ...ove the left crankcase cover 8 3 Remove the seal rubber and dowel pins Remove the kick lever Remove the circlip and washer from the kick starter spindle Gently turn the kick starter spindle to remove...

Page 100: ...driven gear forcing parts for wear or damage INSTALLATION Install the kick starter spindle bushings and return spring onto the left crankcase cover Install the starter driven gear and friction spring...

Page 101: ...PULLEYS KICK STARTER 8 17 Bet Win 125 150 Install the kick lever Install the left crankcase cover and tighten the cover bolts diagonally Connect the drive belt air tube and tighten the band screw Lef...

Page 102: ..._______________________________ __________________________________________________________________________________ __________________________________________________________________________________ FI...

Page 103: ...9 FINAL REDUCTION 9 1 Bet Win 125 150 SCHEMATIC DRAWING...

Page 104: ...TIONS Specified Oil SAE 90 Oil Capacity At disassembly 0 2 liter At change 0 195 liter TORQUE VALUES Transmission case cover bolt 25 5_ 31 4N m Oil check bolt 9 8_ 14 7N m SPECIAL TOOLS Bearing remove...

Page 105: ...rankcase cover 8 3 Remove the clutch driven pulleys 8 4 Drain the transmission gear oil into a clean container Remove the transmission case cover attaching bolts Remove the transmission case cover Rem...

Page 106: ...ive 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 Drive Shaft Bearing Final Shaft Bear...

Page 107: ...he bearing remover Remove the final shaft oil seal Drive new bearings into the transmission case cover BEARING REPLACEMENT LEFT CRANKCASE COVER Remove the drive shaft Remove the drive shaft oil seal R...

Page 108: ...Drive new bearings into the left crankcase Install a new drive shaft oil seal FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Install the final gear and final shaft into the...

Page 109: ...resin washer onto the counter shaft Install the dowel pins and a new gasket Install the transmission case cover Install and tighten the transmission case cover bolts Install the clutch driven pulley I...

Page 110: ...ge 0 18 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 oil to the prop...

Page 111: ..._________________________________________________________________ __________________________________________________________________________________ A C GENERATOR STARTER CLUTCH ______________________...

Page 112: ...10 A C GENERATOR STARTER CLUTCH 10 1 Bet Win 125 150 SCHEMATIC DRAWING...

Page 113: ...ase cover is installed fill with the recommended engine oil and coolant Then bleed air from the water jacket Refer to page 18 4 for A C generator inspection SPECIFICATIONS Engine oil SAE15W 40 API SG...

Page 114: ...hing screws and the pulser coil Remove the three A C generator stator bolts and the stator FLYWHEEL REMOVAL Hold the flywheel with a flywheel holder and remove the flywheel nut Remove the flywheel wit...

Page 115: ...INSPECTION Inspect the starter driven gear for wear or damage Measure the starter driven gear I D and O D Service Limits I D 20 15mm replace if over O D 41 00mm replace if below Inspect the starter i...

Page 116: ...aft Install the starter idle gear and shaft FLYWHEEL INSTALLATION Install the flywheel onto the crankshaft by aligning the key on the crankshaft with the groove in the flywheel Hold the flywheel with...

Page 117: ...l the two dowel pins and a new gasket Install the right crankcase cover over the crankcase aligning the water pump shaft groove with the oil pump shaft Tighten the nine right crankcase cover bolts Con...

Page 118: ...____________________________________________ __________________________________________________________________________________ ________________________________________________________________________...

Page 119: ...11 CRANKCASE CRANKSHAFT 11 1 Bet Win 125 150 SCHEMATIC DRAWING...

Page 120: ...fore separating the crankcase Cylinder head 6 4 Cylinder piston 7 3 Right crankcase cover drive and driven pulley 8 3 A C generator starter clutch 10 3 Rear wheel rear shock absorber 15 4 Starter moto...

Page 121: ...lts Remove the five left crankcase bolts Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase Remove the gasket and dowel pins Remove the crankshaft...

Page 122: ...e the oil seal from the left crankcase CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 6mm replace if over Measure the connecting rod small end I D Service Limi...

Page 123: ...e crankshaft bearing play Service Limits Axial 0 20mm replace if over Radial 0 05mm replace if over CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces Install a new oi...

Page 124: ...Place the right crankcase over the crankshaft and onto the left crankcase Install and tighten the right and left crankcase attaching bolts Torque 7 8_ 10 8N m Left Crankcase Gasket Right Crankcase Do...

Page 125: ...CASE CRANKSHAFT 11 7 Bet Win 125 150 Install the cam chain Install the cam chain tensioner slipper Install and tighten the cam chain tensioner slipper bolt Torque 7 8_ 11 8N m Cam Chain Tensioner Slip...

Page 126: ..._____________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOL...

Page 127: ...12 COOLING SYSTEM 12 1 Bet Win 125 150 SCHEMATIC DRAWING Torque 9 8_ 13 7N m Left Hand Threads...

Page 128: ...ed coolant with fresh water as soon as possible 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 7N...

Page 129: ...2 35 1 063 1 062 1 060 1 058 1 056 1 054 1 052 1 049 1 046 1 043 1 040 40 1 072 1 070 1 068 1 066 1 064 1 062 1 059 1 056 1 053 1 050 1 047 45 1 080 1 078 1 076 1 074 1 072 1 069 1 056 1 063 1 062 1 0...

Page 130: ...tall the radiator tester onto the radiator and apply specified pressure to it It must hold specified pressure for at least six seconds Check the water hoses and connectors for leaks RADIATOR RADIATOR...

Page 131: ...c are clogging the radiator wash them off Carefully straighten any bent fins RADIATOR REMOVAL Drain the coolant 3 9 Disconnect the air vent tube from the radiator filler Remove the overflow tube clamp...

Page 132: ...Disconnect the fan motor wire coupler Remove the two bolts and two nuts on the radiator RADIATOR DISASSEMBLY Remove the four bolts and then remove the fan shroud from the radiator Fan Shroud Radiator...

Page 133: ...ERMOSTATIC SWITCH When coolant temperature lower then 85 90 the thermostatic switch OFF When coolant temperature over 85 90 the thermostatic switch ON Install the fan shroud on the radiator with the f...

Page 134: ...and secure them with hose bands Connect the thermostatic switch wire and fan motor wire couplers Connect the overflow tube and secure with the tube clamp Connect the vent tube to the radiator filler F...

Page 135: ...N 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 WATER PUMP IMPELLER REMOVAL...

Page 136: ...wel pins Remove the water pump impeller Inspect the mechanical water seal and seal washer for wear or damage Impeller Left Hand Threads Mechanical Seal Seal Washer Porcelain Water Pump Cover Bolts The...

Page 137: ...ater pump assembly Remove the water pump assembly gasket and dowel pins Remove the water pump bearing snap ring from the water pump assembly Remove the water pump shaft and shaft inner bearing Remove...

Page 138: ...ew mechanical seal using a mechanical seal driver WATERPUMP SHAFT INSTALLATION Drive a new water pump shaft outer bearing into the water pump assembly from the inside Mechanical Seal Water Seal Mechan...

Page 139: ...ump assembly to the right crankcase cover Tighten the 3 bolts to secure the water pump assembly WATERPUMP IMPELLER INSTALLATION When the mechanical seal is replaced a new seal washer must be installed...

Page 140: ...to the water pump shaft Torque 9 8_ 13 7N m Install the two dowel pins and a new gasket Install the water pump cover and tighten the 4 bolts Torque 7 8_ 11 8N m Impeller Left Hand Threads Dowel Pins W...

Page 141: ...resistance through the sensor as the water heats up Temperature 50 80 100 120 Resistance W 154 52 27 16 THERMOSENSOR INSTALLATION Apply 3 BOND No 1212 sealant or equivalent to the thermosensor threads...

Page 142: ...nsor Disconnect the water hose from the thermostat housing Disconnect the air vent tube from the thermostat housing Remove the mounting bolt and the thermostat housing from the cylinder head Remove th...

Page 143: ...LATION The installation sequence is the reverse of removal Fill the cooling system with the specified coolant 3 9 Do not let the thermostat touch the pan as it will give a false reading Replace the th...

Page 144: ...________ FUEL SYSTEM CARBURETOR FUEL PUMP __________________________________________________________________________________ FUEL SYSTEM 13 1 SCHEMATIC DRAWING 13 2 OPERATION OF CARBURETOR JETS 13 3 S...

Page 145: ...13 FUEL SYSTEM CARBURETOR FUEL PUMP FUEL TANK 13 1 Bet Win 125 150 FUEL SYSTEM...

Page 146: ...13 FUEL SYSTEM CARBURETOR FUEL PUMP FUEL TANK 13 2 Bet Win 125 150 SCHEMATIC DRAWING...

Page 147: ...eed Small Jet Holes 2 MIDDLE SPEED Venturi halfway opened throttle valve High Speed Air Jet Fuel in Float Chamber Main Jet Main Jet The slow jet also works Low Middle Speed Supplementary Device Vacuum...

Page 148: ...fuel pump which utilizes the positive and negative pulsating pressures produced by the engine crankcase to control the oil pump diaphragms and deliver fuel from the fuel tank to the carburetor through...

Page 149: ...ragms All cables fuel lines and wires must be routed and secured at correct locations When removing the fuel tank keep sparks and flames away from the working area When removing the fuel tank the rema...

Page 150: ...re Damaged vacuum piston diaphragm Auto bystarter valve opens excessively Clogged diaphragm hole Faulty float valve Float level too high Lean mixture Clogged air jets Clogged fuel jets Auto bystarter...

Page 151: ...e Loosen the throttle cable adjusting nut and lock nut and disconnect the throttle cable from the carburetor Loosen the air cleaner connecting tube band and carburetor intake manifold band and then re...

Page 152: ...piston Remove the needle holder spring and jet needle from the piston VACUUM PISTON INSPECTION Inspect the vacuum piston and jet needle for wear or damage Inspect the diaphragm for deterioration and...

Page 153: ...CHAMBER DISASSEMBLY Remove the four float chamber screws and the float chamber Remove the float pin float and float valve FLOAT VALVE INSPECTION Inspect the float valve seat contact area for wear Floa...

Page 154: ...main jet needle jet holder needle jet and slow jet with detergent oil Pilot Screw P S Pilot Screw Slow Jet Be sure to use clean detergent oil Main Jet Needle Jet Holder Needle Jet Before removing the...

Page 155: ...rcuit of the carburetor Connect the auto bystarter yellow wire to the positive terminal of a battery and green wire to the negative terminal Wait 5 minutes and blow the hose with mouth If the passage...

Page 156: ...or damage If any faulty part is found replace the auto bystarter with a new one AIR CUT OFF VALVE A C V A C V REMOVAL Remove the two screws and the air cut off valve cover Remove the spring diaphragm...

Page 157: ...LEANING Blow compressed air through all passages of the carburetor body A C V ASSEMBLY Install the O ring onto the air cut off valve body and then install the valve body to the carburetor with the two...

Page 158: ...onnect the hose AUTO BYSTARTER INSTALLATION Install the auto bystarter and set plate Install and tighten the two screws Auto Bystarter Screws Install the O ring with the flat face toward the valve bod...

Page 159: ...in 125 150 FLOAT CHAMBER ASSEMBLY Install the main jet Install the slow jet Install the pilot screw Install the float valve float and float pin Float Valve Float Float Pin Pilot Screw Slow Jet Main Je...

Page 160: ...Y First install the jet needle and spring into the vacuum chamber and then install the needle holder Install the vacuum piston into the carburetor body Install the spring Install the vacuum chamber co...

Page 161: ...all the air cleaner connecting tube and tighten the band Connect the throttle cable to the carburetor Connect the auto bystarter wire Connect the fuel tube and vacuum tube to the carburetor Perform th...

Page 162: ...rame center cover Disconnect the fuel pump inlet outlet and vacuum tubes Remove the two fuel pump attaching bolts and the fuel pump FUEL PUMP DISASSEMBLY Remove the four fuel pump body screws Disassem...

Page 163: ...ve in the fuel pump body for damage cracks or foreign matters FUEL PUMP ASSEMBLY Assemble the fuel pump in the reverse order of disassembly Inlet Spring Suction Valve Diaphragm Outlet Valve Gaskets Re...

Page 164: ...e and place a clean container under the tube to check the fuel output Output 40cc 1500rpm 10 seconds FUEL TANK REMOVAL Remove the floor board 2 4 Remove the leg shield 2 5 Disconnect the fuel unit wir...

Page 165: ...tank INSPECTION Inspect if the fuel strainer is clogged and clean it with compressed air INSTALLATION Install the fuel strainer with its arrow mark toward the fuel pump When removing the fuel straine...

Page 166: ..._________________________ __________________________________________________________________________________ __________________________________________________________________________________ STEERING...

Page 167: ...14 STEERING HANDLEBAR FRONTWHEEL FRONT BRAKE FRONTSHOCKABSORBER FRONTFORK 14 1 Bet Win 125 150 SCHEMATIC DRAWING...

Page 168: ...0 2 Radial 2 0 Axial 2 0 Front shock absorber spring free length 240 6 233 Brake disk thickness 3 8_ 4 2 3 0 Brake disk runout 0 30 Brake master cylinder I D 12 70_ 12 74 12 75 Brake master cylinder...

Page 169: ...side or does not track straight Improperly tightened axle nut Uneven front shock absorbers Soft front shock absorber Bent front fork Weak shock springs Bent front axle or uneven tire Insufficient damp...

Page 170: ...the leg shield 2 5 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 Remove th...

Page 171: ...EL 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 INSPECTION AXLE RUNOUT Set the axle in V b...

Page 172: ...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 bea...

Page 173: ...y aligning the speedometer gear unit groove with the front shock absorber tab Insert the axle and tighten the axle nut Torque 44 1_ 49N m Tab Do not allow the bearings to tilt while driving them in Dr...

Page 174: ...ever bolt and the brake lever Remove the piston rubber cover and snap ring from the brake master cylinder Remove the washer main piston and spring from the brake master cylinder Clean the inside of th...

Page 175: ...spring and snap ring Install the rubber cover Install the brake lever Place the brake master cylinder on the handlebar and install the holder with the up mark facing up Also align the punch mark with...

Page 176: ...the brake fluid until there is no air bubbles in the brake fluid Then tighten the bleed valve Repeat these steps until the brake system is free of air Brake fluid spilled on brake pads or brake disk...

Page 177: ...ake caliper Remove the brake pads 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...

Page 178: ...l Lubricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved side facing out Wipe off excessive brake fluid with a clean shop towel Apply silicon g...

Page 179: ...rake 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 14 10 Fluid Tube B...

Page 180: ...al Remove the circlip Set the front shock absorber in a vise Remove the damper rod hex bolt and copper washer Pull out the front shock absorber tube Set the front shock absorber tube in a vise Remove...

Page 181: ...TION Inspect the following items and replace if necessary Front shock absorber tube bending damage or wear Weak front shock absorber spring Damper and damper rod bending Oil seal damage or wear Measur...

Page 182: ...ghten the damper rod hex bolt Add engine oil into the front shock absorber Torque 4 9_ 29 4N m Specified Oil SS 8 Oil Capacity 81cc Install the oil seal Install the circlip Install the dusts seal and...

Page 183: ...e race and remove the steering stem lock nut Remove the top cone race and remove the front fork Inspect the ball races cone races and steel balls for wear or damage Replace if necessary BOTTOMCONERACE...

Page 184: ...right and left several times to make steel balls contact each other closely Install the steering stem lock nut and tighten it while holding the top cone race Torque 78 4_ 117 6N m Install the front wh...

Page 185: ...___________________________________________ __________________________________________________________________________________ _________________________________________________________________________...

Page 186: ...15 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 15 1 Bet Win 125 150 SCHEMATIC DRAWING...

Page 187: ...0_ 25 45 25 45 Rear brake caliper piston O D 25 335_ 25 368 25 30 TORQUE VALUES SPECIAL TOOLS Exhaust muffler lock bolt 29 4_ 39 2N m Rear shock absorber remover Rear axle nut 78 4_ 98N m Shock absorb...

Page 188: ...r brake caliper 14 11 Inspect and assemble the rear brake caliper 14 12 Note The rear brake caliper and front brake caliper have the same specification INSTALLATION Install the brake caliper to the re...

Page 189: ...ith 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 t...

Page 190: ...dium C position hard When you adjust rear cushion the spring preload of rear cushions must be the same REAR SHOCK ABSORBER REMOVAL Remove the rear carrier and hand rail 2 3 Remove the met in box 2 3 R...

Page 191: ...erioration or damage Measure the front shock absorber spring free length Service Limit Right 226mm Left 226mm ASSEMBLY Assemble the rear shock absorbers in the reverse order of disassembly INSTALLATIO...

Page 192: ..._______ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY CHARGING SYSTEM __...

Page 193: ...16 BATTERY CHARGING SYSTEM 16 1 Bet Win 125 150 CHARGING SYSTEM LAYOUT CHARGING CIRCUIT Fuse Regulator Rectifier A C Generator Battery...

Page 194: ...ooting Do not disconnect and soon reconnect the power of any electricalequipment because the electronic parts in the regulator rectifier will be damaged Turn off the ignition switch before operation I...

Page 195: ...nnection Disconnected battery cable Loose charging system connection Fuse burned out Loose connection or short circuit in Faulty ignition switch ignition system Low power Charging system failure Weak...

Page 196: ...andard 0 9A Quick 4A Charging time Standard 5_ 10 hours Quick 30 minutes After charging Open circuit voltage 12 8Vmin Battery Cover Screw When disconnecting the battery positive cable do not touch the...

Page 197: ...ORMANCE TEST Engine Speed 2500rpm 5000rpm Charging Current 6A min 8A min If the readings do not meet the specified values check the regulator rectifier A C GENERATOR INSPECTION Remove the frame center...

Page 198: ...irection Continuity Probe Probe I Yellow Green II Red Black Yellow Reverse Direction No Continuity Probe Probe I Green Yellow II Yellow Red Black VOLTAGE REGULATION TEST Connect a voltmeter across the...

Page 199: ...0 15_ 2 5 4_ 8 Charging indicator inspection 1 Turn on the ignition switch The Charging lamp should be lighten 2 Start the engine The Charging lamp should be went out 3 Inspect the output voltage of C...

Page 200: ...__________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM...

Page 201: ...17 IGNITION SYSTEM 17 1 Bet Win 125 150 IGNITION SYSTEM LAYOUT IGNITION CIRCUIT Pulser Coil Ignition Switch Ignition Coil CDI Unit A C Generator...

Page 202: ...erator and pulser coil referring to Section 10 SPECIFICATIONS Item Standard Standard type NGK DP7EA9 Spark plug Hot type NGK DP6EA9 Cold type NGK DP8EA9 Spark plug gap 0 8_ 1 0mm Ignition timing F mar...

Page 203: ...he continuity of the ignition coil primary coil and secondary coil Measure the ignition coil resistances at 20 SECONDARY COIL WITH PLUG CAP Primary coil 0 16_ 1W Secondary coil without plug cap 3 4_ 4...

Page 204: ...ire terminal and ground Black red_ Ground 50_ 250W For A C generator removal installation refer to pages 10 3 and 10 6 Disconnect the pulser coil wire coupler Measure the pulser coil resistance betwee...

Page 205: ...swings then returns Needle swings then returns PC Blue Yellow 5 50 30 100 20 80 E Green Green White 5 20 1 10 5 40 IGN Black Yellow IGN Black Yellow PC Blue Yellow EXT Black Red SW Black White E Gree...

Page 206: ...__________________________________ __________________________________________________________________________________ __________________________________________________________________________________...

Page 207: ...18 STARTING SYSTEM 18 1 Bet Win 125 150 STARTING SYSTEM LAYOUT STARTING CIRCUIT Starter Relay Starter Button Starter Motor Stop Switches...

Page 208: ...m TORQUE VALUES Starter motor mounting bolt 6 7_ 10 8N m Starter motor case screw 2 9_ 4 9N m Starter clutch bolt 9 8_ 13 7N m SPECIAL TOOLS Flywheel holder Flywheel puller TROUBLESHOOTING Starter mot...

Page 209: ...ar damage or discoloration Replace if necessary Clean the commutator if there is metal powder between the segments Check for continuity between pairs of the commutator segments and there should be con...

Page 210: ...ontinuity between the wire terminal and each brush Replace if necessary Measure the length of the brushes Service Limit 8 5mm replace if below Check for continuity between the brushes If there is cont...

Page 211: ...rter motor case aligning the tab on the motor case with the groove on the front cover Tighten the starter motor case screws INSTALLATION Connect the starter motor cable Check the O ring for wear or da...

Page 212: ...ontinuity check the starter button for continuity and inspect the wire OPERATION TEST Connect the electric tester to the starter relay larger terminals that connect to the battery positive cable and t...

Page 213: ...____________________________________________________________________________ __________________________________________________________________________________ SWITCHES HORN FUEL UNIT THERMOSTATIC SWI...

Page 214: ...INSTRUMENTS LIGHTS 19 1 Bet Win 125 150 ELECTRICAL EQUIPMENT LAYOUT Turn Signal Switch Stop Switches Horn Button Headlight Dimmer Switch Fuel Unit Starter Button Horn Ignition Switch Auto Bystarter T...

Page 215: ...mperature gauge does not register switch is ON correctly Burned bulb Faulty temperature gauge Faulty switch Faulty thermosensor Poorly connected broken or shorted wire Broken or shorted wire between t...

Page 216: ...t covers 2 5 Disconnect the headlight switch wire couplers Check for continuity between the wire terminals Color Position White Blue Brown Blue Brown n P H STARTER SWITCH INSPECTION Remove the frame f...

Page 217: ...heck for continuity between the wire terminals Color Position Light Blue White Gray Orange White L N R DIMMER SWITCH INSPECTION Remove the frame front covers 2 5 Disconnect the headlight dimmer switch...

Page 218: ...45W 500_ 850 W L W_ G 400_ 700 W 100_ 200 W Y W_ L W 450_ 750 W 450_ 750 W FUEL GAUGE INSPECTION Connect the fuel unit wire connectors and turn the ignition switch ON Check the fuel gauge needle for c...

Page 219: ...ack_ green If there is no voltage check for the following Blown or faulty fuse Loose terminals or connectors Shorted wire in the wire harness TEMPERATURE GAUGE Disconnect the wire from the thermosenso...

Page 220: ...e speedometer cable Remove the four instrument cover and leg shield screws Remove the instruments DISASSEMBLY ASSEMBLY Remove the three instrument holder nuts Remove the holder Remove the four screws...

Page 221: ...nnect the headlight and turn signal light wire couplers Remove the bulb sockets by turning them counterclockwise Remove the bulbs and replace them with new ones FRONT TURN SIGNAL LIGHT BULB REPLACEMEN...

Page 222: ...19 SWITCHES HORN FUELUNIT THERMOSTATICSWITCH TEMPERATUREGAUGE INSTRUMENTS LIGHTS 19 9 Bet Win 125 150 HEATER WIRING DIAGRAM...

Page 223: ...ER INSTALLATION 6 11 CYLINDER HEAD COVER REMOVAL 6 4 CYLINDER HEAD DISASSEMBLY 6 7 CYLINDER HEAD INSTALLATION 6 9 CYLINDER HEAD REMOVAL 6 6 CYLINDER INSTALLATION 7 7 CYLINDER REMOVAL 7 3 DRIVE BELT 3...

Page 224: ...INSPECTION 16 6 RIGHT CRANKCASE COVER INSTALLATION 10 6 RIGHT CRANKCASE COVER REMOVAL 10 3 SCHEMATIC DRAWING 10 1 SCHEMATIC DRAWING 11 1 SCHEMATIC DRAWING 12 1 SCHEMATIC DRAWING 13 2 SCHEMATIC DRAWIN...

Page 225: ...17 THERMOSTATIC SWITCH 19 6 THROTTLE OPERATION 3 3 TOOLS 1 9 TORQUE VALUES 1 8 TROUBLESHOOTING 10 2 TROUBLESHOOTING 11 2 TROUBLESHOOTING 1 18 TROUBLESHOOTING 12 2 TROUBLESHOOTING 14 3 TROUBLESHOOTING...

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Summary of Contents for Bet & Win 125

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KYMCO Bet & Win 125, User Manual, Page: 62 / 225

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Summary of Contents for Bet & Win 125

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